Masonry & Tile
Black and Decker The Complete Guide to Masonry and Stonework 3e
Source: Black and Decker The Complete Guide to Masonry and Stonework 3e.pdf
Source file: Black and Decker The Complete Guide to Masonry and Stonework 3e.pdf
NEW 3rd Edition DVD INCLUDED THE COMPLETE GUIDE TO
MASONRY & STONEWORK Updated with New Products & Techniques • Poured Concrete • Brick & Block • Natural Stone • Stucco
DVD
INCLUDEDTHE COMPLETE GUIDE TO
MASONRY & STONEWORK Updated with New Products & Techniques • Poured Concrete • Brick & Block • Natural Stone • Stucco
MINNEAPOLIS, MINNESOTA
www.creativepub.comCopyright © 2010 President/CEO: Ken Fund Creative Publishing international, Inc. 400 First Avenue North, Suite 300 Home Improvement Group Minneapolis, Minnesota 55401 1-800-328-0590 Publisher: Bryan Trandem www.creativepub.com Managing Editor: Tracy Stanley All rights reserved Senior Editor: Mark Johanson Editor: Jennifer Gehlhar Printed in China Creative Director: Michele Lanci-Altomare 10 9 8 7 6 5 4 3 2 1 Art Direction/Design: Jon Simpson, Brad Springer, James Kegley
The complete guide to masonry & stonework. — 3rd ed. Lead Photographer: Joel Schnell p. cm. Set Builder: James Parmeter Includes index. Production Managers: Linda Halls, Laura Hokkanen At head of title: Black & Decker. “Poured concrete, brick & block, natural stone, stucco.” Page Layout Artist: Parlato Design Studio Summary: “Includes traditional techniques for laying concrete, as well Shop Help: Charles Boldt as new materials and techniques, such as tumbled concrete pavers, Edition Editor: Kristen Hampshire acid-etching for colored concrete slabs,and important green paving Copy Editor: Mark Kakkuri options, such as rain garden arroyos and permeable pavers”— Proofreader: Leah Noel Provided by publisher. ISBN-13: 978-1-58923-520-5 (soft cover) ISBN-10: 1-58923-520-7 (soft cover)
- Stonemasonry. I. Black & Decker Corporation (Towson, Md.) II. Title: Complete guide to masonry and stonework.
TH5401.C655 2010 693’.1—dc22
2009048793
The Complete Guide to Masonry & Stonework Created by: The Editors of Creative Publishing international, Inc. in cooperation with Black & Decker. Black & Decker® is a trademark of The Black & Decker Corporation and is used under license.
NOTICE TO READERS For safety, use caution, care, and good judgment when following the procedures described in this book. The Publisher and Black & Decker cannot assume responsibility for any damage to property or injury to persons as a result of misuse of the information provided. The techniques shown in this book are general techniques for various applications. In some instances, additional techniques not shown in this book may be required. Always follow manufacturers’ instructions included with products, since deviating from the directions may void warranties. The projects in this book vary widely as to skill levels required: some may not be appropriate for all do-it-yourselfers, and some may require professional help. Consult your local Building Department for information on building permits, codes and other laws as they apply to your project.
Contents 17 18
The Complete Guide to Masonry & Stonework
36 44Introduction … … … … … … … … … . 7
Gallery of Masonry & Stonework … … … … … … … … .8
POURED CONCRETE … … … … … … … 19
Concrete Basics … … … … … … … … … … … … .18 56 62
Preparing a Project Site … … … … … … … … … … .36
Setting Concrete Posts … … … … … … … … … … .42
Concrete Piers … … … … … … … … … … … … . .44
Poured Footings for Freestanding Walls … … … … … . . .46
Poured Concrete Walkway… … … … … … … … … . .50 72
Concrete Steps… … … … … … … … … … … … . .56
Entryway Steps … … … … … … … … … … … … .62
Poured Concrete Slab … … … … … … … … … … . .68
Round Patio … … … … … … … … … … … … … .72
Poured Concrete Wall … … … … … … … … … … . .80 80 94
Poured Concrete Retaining Wall … … … … … … … . . .86
Cast Concrete … … … … … … … … … … … … . .94
Kitchen Countertop … … … … … … … … … … . . .100
BRICK & BLOCK … … … … … … … . . 109 100
Brick & Block Basics… … … … … … … … … … . . .110
Dry Block Wall … … … … … … … … … … … … .130
Block Retaining Wall… … … … … … … … … … . . .132
Outdoor Kitchen… … … … … … … … … … … . . .138
Brick Barbecue … … … … … … … … … … … … .146 110 138
Contents (Cont.)
150
156Brick Planter… … … … … … … … … … … … . . .150
Brick Pillars… … … … … … … … … … … … … .152
Brick Archway … … … … … … … … … … … … .156
Brick Wall Veneer … … … … … … … … … … … . .160
Mortared Brick Patio … … … … … … … … … … . .164 164 170
NATURAL STONE … … … … … … … . 169
Natural Stone Basics … … … … … … … … … … . .170
Dry Stone Wall … … … … … … … … … … … … .182
Mortared Stone Wall … … … … … … … … … … . .184 182
Stone Retaining Wall … … … … … … … … … … . .188
Arroyo (Dry Streambed) … … … … … … … … … . . .194
Stone Firepit… … … … … … … … … … … … . . .198
Mortared Flagstone Patio … … … … … … … … … .202
Flagstone Garden Steps… … … … … … … … … . . .206 194 198
Rock Garden… … … … … … … … … … … … . . .212
Stone Moon Window … … … … … … … … … … . .214
Cobblestone Paver Patio … … … … … … … … … . .218
Sandset Flagstone Patio … … … … … … … … … . .226 214 219 Pebbled Stepping Stone Path … … … … … … … … .232
Zen Garden… … … … … … … … … … … … … .234
DECORATIVE MASONRY FINISHING… … . . 239
Stamped Concrete Finishes… … … … … … … … . . .240
Acid-stained Concrete Patio … … … … … … … … . .242 234
Contents (Cont.)
242 244
250 256Decorative Concrete Floor… … … … … … … … … .244
Stucco Finish … … … … … … … … … … … … . .250
Stone Veneer … … … … … … … … … … … … . .256
Mortarless Brick Veneer Siding … … … … … … … . . .262
Tiling a Concrete Slab … … … … … … … … … … .268 262 268
Tiling Concrete Steps … … … … … … … … … … . .276
REPAIR & MAINTENANCE … … … … … 283
Repairing Concrete … … … … … … … … … … . . .284
Patching Cracks … … … … … … … … … … … . . .286
Quick Fixes for Wet Walls… … … … … … … … … . .288
Renewing an Old Concrete Slab … … … … … … … . .290
Repairing Steps … … … … … … … … … … … . . .294
Miscellaneous Concrete Repairs … … … … … … … . .296
Brick Repairs … … … … … … … … … … … … . .298 276
Repairing & Replacing Chimney Caps … … … … … … .302
Repairing Stonework … … … … … … … … … … . .304
Repairing Stucco … … … … … … … … … … … . .308
Pressure-washing Masonry … … … … … … … … . . .310 284
Conversion Table … … … … … … … . 312
Resources… … … … … … … … … . 313
Photography Credits … … … … … … . 313
Index … … … … … … … … … … . 314 298 310
Introduction M asonry is a popular home building material for many reasons, including its beauty, versatility, and resistance to fire, earthquakes, and sound transmission. And let’s not forget its remarkable durability. While few of us imagine that our homes will exist for centuries, when we choose masonry we’re choosing a material that has precisely that capability. Some of the world’s most venerable masonry structures—the Taj Mahal, the Egyptian Pyramids, the Colosseum in Rome, the Great Sphinx of Giza—have awed countless generations with their ability to withstand time.
Poured Concrete introduces you to the tools, materials, and basic techniques necessary for accomplishing functional and attractive concrete projects. You’ll learn foundation skills that allow you to build projects ranging from foundations to retaining walls and for inside, a kitchen island countertop. We walk you through each project, step-by-step, providing illustrative photos to guide the way.
Brick & Block includes projects such as building a brick barbecue and laying a mortared brick patio. You’ll learn the tools, materials, and skills necessary to complete basic brick projects and sophisticated designs. A comprehensive section of projects gives you an opportunity to explore the possibilities of brick and block as a functional, long-lasting, and aesthetically pleasing construction medium.
Natural Stone introduces fresh design interpretations for an age-old material. Versatile and texturally interesting, natural stone is an increasingly popular landscaping material, and a robust selection of paver materials that resemble old-world stone are accessible and easy to use in building projects. We’ll show you the various types of stone, how to choose appropriate material for your project, and techniques you’ll want to master before taking on the projects in this book. Then, we give you a portfolio of natural stone ideas and step-by-step instructions to accomplish them at home.
Decorative Masonry Finishing shows you how to add interest to concrete surfaces, install veneer siding, and accomplish a stucco finish. These skills will help you customize other projects in this book.
Repair & Maintenance teaches you how to make quick fixes and take on more substantial repair projects to keep your masonry and stonework projects in top condition.
So, dig in! Peruse each section and earmark projects that interest you. You may want to make a priority list—one project inevitably leads to another. Consider yourself a masonry apprentice learning a time-honored craft and let us expose you to the hands-on techniques and creative possibilities.
■ 7Gallery of Masonry & Stonework
I n their raw state, concrete and rocks are about the most humble building materials you can find. But add some inspiration and a little hard work, and you’ll be amazed at the feats that can be accomplished with these simple products. The projects featured on the following pages are just a sampling of the beauty of masonry.
Stone slabs placed in a slope create natural garden steps in casual or formal settings.
A natural stone retaining wall and mortared flagstone driveway add structural interest to this home and provide a formal entryway.
8 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Natural clay tile and a clay brick garden wall are separated This stacked stone wall provides the framework for an by a border of light porcelain tiles. The contrasting porcelain outdoor kitchen. It combines natural and cast stones. color creates a visual bridge between the slightly differing brick tones of the patio and wall.
Stucco is a very popular and highly durable siding product Blocks, pavers, and natural stone all find a home in this that is created using modified masonry materials, tools, landscape. Included are two retaining walls (one cut stone, and techniques. one interlocking block with cast capstones), a concrete paver walkway, and well-chosen landscape boulders.
Gallery of Masonry & Stonework ■ 9Terracing is a landscaping technique in which a series of retaining walls are built to break up a slope into small, flat areas.
Cast cobble stones emulate the look Cast concrete can be formed into a Poured concrete sidewalks don’t of natural stone paving, with tumbled host of useful and decorative items for need to be straight and uniform. Curves surfaces and random coloration. They the garden, such as this planter cast in a go a long way toward visually softening are usually laid in regular patterns. 5-gallon bucket. this rock-hard material.
10 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Veneer stone has a refined, timeless appearance that is a very convincing imitation of natural stone. Because the manmade product weighs less than natural stone and is engineered for ease of installation, it is a very practical solution for siding your home.
Brick veneer transforms these
cast concrete column bases from
unremarkable to elegant. The resulting
posts have the strength and durability of
concrete and the beauty of brick.
Gallery of Masonry & Stonework ■ 11The massive presence of concrete is used to great design advantage in the cast concrete elements found in the patio and fireplace above. The simple lines and monochromatic tones give the patio a contemporary feel.
Concrete pavers in various sizes and shapes add visual appeal when used in stairs and as planters.
12 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Cast stepping stones allow landscapers to apply creative touches to the otherwise plain concrete gray tones. In this case, the gaps between stepping stones are filled with crushed gravel.
Gallery of Masonry & Stonework ■ 13The exposed aggregate squares in this concrete patio take on the look of high-end landscape design because they are separated into a grid bordered by brick pavers.
14 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Curves and nonlinear designs add great visual interest and A stairway landing is used to create a resting place and to create natural stopping points near landscape features. allow you to adjust the stairway design so all of the treads are the same depth.
Cut flagstone patios and walkways are more formal in appearance and easier to walk on than surfaces made with uncut flags.
Gallery of Masonry & Stonework ■ 15Poured Concrete P oured concrete is versatile, sturdy, and highly functional for walkways, foundations, and even decorative features like garden steps. Concrete is back-to-the-basics—a standard material because of its weather-ready qualities and ability to stand the test of time. Plus, with today’s creative applications for poured concrete you’ll enjoy customizing a slab, experimenting with casting, and learning how to pour structures that will enhance your living environment.
In this chapter: • Concrete Basics • Preparing a Project Site • Setting Concrete Posts • Concrete Piers • Poured Footings for Freestanding Walls • Poured Concrete Walkway • Concrete Steps • Entryway Steps • Poured Concrete Slab • Round Patio • Poured Concrete Wall • Poured Concrete Retaining Wall • Cast Concrete • Kitchen Island Countertop
■ 17Poured concrete might not be the first material that comes to mind when dreaming of a new garden wall, but it’s certainly worth consideration. The versatility of concrete can inspire all sorts of custom creations, such as this retaining wall with a traditional frame-and-panel effect.
18 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Concrete Basics
D urable, versatile, and economical, poured concrete can be shaped and finished into a wide variety of surfaces and structures throughout your home and Good preparation means fewer delays at critical moments and leaves you free to focus on placing and smoothing the concrete—not on staking loose forms yard. Decorative surfaces and unique appearances can or locating misplaced tools. Before beginning to mix be produced with exposed aggregate, tints and stains, or pour the concrete, make sure the forms are sturdy and special stamping tools. enough to stand up to the weight and pressure that Pouring footings or a foundation is the first step to will be exerted on them and that they are staked and many hardscape projects, such as fences, walls, sheds, braced well. Forms that are taller than four or five and decks or gazebos, and is an excellent introduction to inches should be tied with wire. The joints on the working with concrete. Pouring a small sidewalk or patio forms should be tight enough that the bleed water is a good way to learn about finishing concrete. It’s best doesn’t run through them. to save larger projects, such as driveways and large patios, One of the most difficult aspects of finishing until you are comfortable working with and finishing concrete is recognizing when it’s ready. Many people concrete and have plenty of assistants on hand to help you. try to rush the process, with disappointing results. Planning and preparation are the keys to Wait until the bleed water disappears and the concrete successful concrete projects. Poured concrete yields has hardened somewhat before floating the surface. the most durable and attractive final finish when it A good rule of thumb is when the footprints you leave is poured at an air temperature between 50 and 80 are light enough that you can no longer identify the degrees F and when the finishing steps are completed type of shoes you are wearing, the concrete is ready to carefully in the order described in the following pages. be worked.
Components of Concrete ▸
Aggregate
Sand
Clean water
Portland cement
The basic ingredients of concrete are the same, whether the concrete is mixed from scratch, purchased premixed,
or delivered by a ready-mix company. Portland cement is the bonding agent. It contains crushed lime, cement, and
other bonding minerals. Sand and a combination of aggregates add volume and strength to the mix. Water activates the
cement, and then evaporates, allowing the concrete to dry into a solid mass. By varying the ratios of the ingredients,
professionals can create concrete with special properties that are suited for specific situations.
Poured Concrete ■ 19■ Tools & Materials A A B
D
B
C
CLayout and measuring tools for preparing jobsites and Other useful tools include: a carpenter’s square (A), a installing and leveling concrete forms include a tape measure chalkline (B), a laser level (C), and a combination laser level and (A), a 4-ft. level (B), and a 2-ft. level (C). stud finder (D).
D
C
E
A
B
F
G
HLandscaping tools for preparing sites for concrete projects include: power auger (A) for digging holes for posts or poles; pick (B) for excavating hard or rocky soil; weed trimmer (C) for removing brush and weeds before digging; power tamper (D) and power sod cutter (E) for driveway and other large-scale site preparation; come-along (F) for moving large rocks and other heavy objects; garden rake (G) for moving small amounts of soil and debris; and posthole digger (H) for when you have just a few holes to dig.
20 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
CA
B
B
C ASafety tools and equipment include: gloves (A), safety Mixing and pouring tools include: masonry hoe and glasses (B), particle masks (C), and tall rubber boots (not shown). mortar box (A) for mixing small amounts of concrete; garden Wear protective gear when handling dry or mixed concrete. These hose and bucket (B) for delivering and measuring water; and mixes are very alkaline and can burn eyes and skin. When mixing power mixer (C) for mixing medium-sized (between 2 and dry bagged concrete, a half-mask respirator is good insurance. 4 cu. ft.) loads of concrete.
A
D
C M
B
E I
F
G
H
L
J KFinishing tools include: outside corner tool (A); aluminum darby (B) for smoothing screeded concrete; screed board (C) for striking off placed concrete; long wood float (D); trowel (E); groover (F) for forming control joints; edger (G) for shaping and forming edges; standard-length wood float (H); square-end trowel (I) for finishing; inside corner tool (J); a steel trowel (K); mason’s trowel (L); and long-handled bull float (M) for smoothing large slabs.
Poured Concrete ■ 21
Bagged concrete mix comes in many
D
formulations. The selection you’re likely
to encounter varies by region and by
time of year, but the basic products most
home centers stock include: all-purpose
B concrete (A, C) for posts, footings, and
C slabs; sand mix (B) for topping and
casting; Portland cement (D) for mixing
with aggregate, sand, and water to make
your own concrete; high/early concrete
A (E) for driveways and other projects
that demand greater shock and crack
resistance; fast-setting concrete (F) for
setting posts and making repairs; specialty
E
blends for specific purposes, such as
countertop mix (G,) which comes premixed
with polyester fibers and additives that
make it suitable for countertops.
F
G
Liquid concrete products are either added
to the concrete mix while blending or applied
after the concrete sets up. Concrete sealer
A B (A) is added to the concrete while liquid for
even coloring that goes all the way through
the material. Dry pigments also may be added
to the wet mixture or scattered onto the
surface of concrete slabs during the troweling
stage. Bonding additive (B) is applied (usually
by roller or sprayer) to protect the concrete
from moisture penetration and to give it a
deeper, wet-look finish. The product seen here
also encourages proper curing when applied
immediately after the concrete dries. Concrete
colorant (C) is added to dry mix instead of
water to make the concrete more elastic and
to help it grab onto old concrete surfaces.
Also called acrylic fortifier or latex bonding
agent, it can be painted onto the old concrete
surfaces, as well as the new, to increase
concrete adhesion. Stucco and mortar color
D (D) can be added to finish coat stucco, mason
C mix, surface-bonding cement, and heavy-duty
masonry coating. It is often premixed with water.22 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
F
B
E
C
A
DMaterials for sub-bases and forms include: lumber (A) and 3” screws (C) for building forms, vegetable oil (B) or a commercial release agent to make it easier to remove the forms, compactable gravel (D) to improve drainage beneath the poured concrete structure, asphalt- impregnated fiberboard (E) to keep concrete from bonding with adjoining structures, and stakes (F) for holding the forms in place.
D
A A B
B E
F
C
D
C
G
HReinforcement materials: Metal rebar (A, B), available Masonry fasteners allow you to mount objects to concrete in sizes ranging from #2 (1⁄4” diameter) to #5 (5⁄8” diameter) and other masonry surfaces. It is most effective to embed reinforce concrete slabs, like sidewalks, and masonry walls; the fasteners in fresh concrete so that it cures around the for broad surfaces, like patios, bolsters (C) support rebar and hardware. Examples include: J-bolt with nuts and washers wire mesh; wire mesh (D) (sometimes called remesh) is most (A, B); removable T-anchor (C); metal sleeve anchor (D); common in 6 × 6” grids. compression sleeves (E, G); light-duty plastic anchor sleeve (F); self-tapping coated steel screws (H).
Poured Concrete ■ 23■ Planning Concrete Projects There are two basic stages to planning and designing a concrete project. First is the idea-gathering phase: Employ a variety of sources to help answer questions such as “What qualities will make your project attractive, practical, and durable?” Consider these goals as you plan. Second, apply the basic standards of construction to create a sound plan that complies with local building codes. The projects in this book outline those processes. Begin by watching for good ideas wherever you go. As you walk through your neighborhood, look for similar projects and observe detail and nuance. Once you’ve settled on a plan, test the layout by using a rope or hose to outline the proposed project areas. Remember that successful structures take into account size and scale, location, slope and drainage, reinforcement, material selection, and appearance. It’s also advisable to take your own level of skills and experience into account, especially if you haven’t worked with poured concrete before. Finally, develop plan drawings for your project. If it’s a simple project, quick sketches may be adequate. If permits will be necessary for your project, the building inspector is likely to request detailed plan drawings. (Always check with the local building department early in the planning process.) Either way, drawings help you recognize and avoid or deal with challenges inherent to your project.
Make scaled plan drawings using graph paper and drafting Test project layouts before committing to your ideas. Use tools. Plan drawings help you eliminate design flaws and a rope or hose to outline the area, placing spacers where accurately estimate material requirements. necessary to maintain accurate, even dimensions.
24 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Estimating Concrete Plan drawings are especially valuable when the time Coverage rates for poured concrete are determined comes to estimate materials. With your drawing in by the thickness of the slab. The same volume of hand, calculate the width and length of the project concrete will yield less surface area if the thickness of in feet, and then multiply the dimensions to get the the slab is increased. square footage. Measure the thickness in feet (four Unless you need to improve the drainage or inches thick equals one-third of a foot), and then the soil stability of your building site, the only other multiply the square footage times the thickness to raw material you’ll need for most pours is sub-base the get the cubic footage. For example, 1 foot × 3 material, such as compactable gravel. Gravel is feet × 1⁄3 foot = 1 cubic foot. Twenty-seven cubic normally sold by the cubic yard. For a slab with a feet equals one cubic yard. four- to six-inch–thick sub-base, one cubic yard of gravel will cover 60 to 70 square feet of surface.
1 cubic foot Concrete Coverage ▸
Volume Slab thickness Surface area
1 cu. yd. 2" 160 sq. ft.
3 ft. long 1 cu. yd. 3" 110 sq. ft.
1 cu. yd. 4" 80 sq. ft.
1 cu. yd. 5" 65 sq. ft.
1 cu. yd. 6" 55 sq. ft.
1 cu. yd. 8" 40 sq. ft.
This chart shows the relationship between slab thickness,
4” thick
surface area, and volume.
1 ft. wideEstimate the materials required based on the dimensions of your project.
Estimating Concrete for Tube Format ▸
Footing Number of 60-lb. bags for Footing Number of 80-lb. bags for
depth each size (diameter of tube) depth each size (diameter of tube)
6" 8" 10" 12" 6" 8" 10" 12"
1 ft. 1 1 2 2 1 ft. 1 1 1 2
2 ft. 1 2 3 4 2 ft. 1 2 2 3
3 ft. 2 3 4 6 3 ft. 2 3 3 4
4 ft. 2 4 5 7 4 ft. 2 3 4 6This chart shows the number of bags of concrete mix a footing requires.
Poured Concrete ■ 25■ Ordering Concrete For concrete pours where more than one cubic yard readymix delivered assures that you will be getting of concrete is required, it usually makes sense to find quality material that is customized for your project. an alternative to mixing the concrete in small batches. When you contact your local, reputable concrete In most cases, this means ordering premixed concrete supplier, the first question he or she will ask is “What (called readymix) and having it delivered in a concrete are you building?” The answer to this (driveway, truck to your jobsite. This will increase the concrete foundation wall, patio, etc.) allows the supplier cost considerably, especially for smaller pours of one to design a mixture that has just the right ratios to two cubic yards (most concrete mixing trucks can of ingredients and admixtures that you need. The carry up to six cubic yards, but this is more than a concrete is further customized on the day of the pour DIYer typically can deal with in one shot). The cost as a good supplier will factor in the weather conditions of the material itself is comparable to buying bagged and the distance from the plant to your house when concrete and mixing it yourself, but the minimum making the final blend of concrete. The result is a delivery charge often exceeds the cost of the material custom blend that will almost certainly outperform and drives up the total cost. anything you can whip up by just adding water. But of In addition to saving all the time and energy course, the tradeoff is higher cost and the inability to that is required for mixing concrete by hand, having control the timing of the pour.
For larger pours there really is no good
alternative to having readymix concrete
delivered. Once you factor in the delivery
charges, it costs a good deal more than
mixing your own from bags, but the quality
of the material is consistently superior.
Are You Ready for Delivery? ▸
1. Are all concrete forms built and staked? 8. Do you have at least two heavy-duty wheelbarrows
2. Has reinforcement (rebar or remesh) been placed (and strong helpers to run them) on site?
inside the forms as required? 9. Are trowels, floats, and screeds clean and ready to go?
3. Has clean fill been placed in form as required (mostly 10. Do you have a concrete vibrator rented and on site,
used with steps)? if required?
4. Have forms been treated with a release agent? 11. Have you constructed a ramp for wheelbarrows
5. Have any required permits to block the sidewalk or to scale forms and get inside project area
street been obtained? Ask your concrete supplier for (where required)?
more information. 12. Have you confirmed the delivery time, amounts, and
6. Has a path from the truck parking spot to the project type of concrete with the readymix supplier?
been cleared? 13. VERY IMPORTANT: Have your forms been
7. Have you consulted with the readymix supplier to inspected and approved by your local
determine if wheelbarrows will be necessary? building department?26 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How Much Does Concrete Cost? The actual costs of buying bagged concrete or having if you use special blends the cost will go upward concrete mixed and delivered to your site can be hard very fast. High-strength and fast-setting concrete to predict. Like gasoline or plywood, concrete is a cost about twice as much as general-purpose, and commodity and is subject to fairly wild price fluctuations special purpose mixtures, such as countertop, as market conditions change. The costs also vary quite concrete can cost five times as much. a bit regionally and seasonally. But for the sake of comparison, here are the results of some recent price shopping (quotes obtained on the same day in the same READYMIX CONCRETE IN DIY TRAILER city), along with some notes on each method. Trailer rental: Waived with purchase Cost of 1⁄2 cubic yard: $117 BAGGED CONCRETE MIXED BY HAND: Cost of 1 cubic yard: $155 Cost of materials: $3.50 per 80 lb. bag (general-purpose concrete) Notes: 80 lb. bags per cubic yard: 41 • If you will be pulling the trailer with a vehicle Cost of 1 cubic yard: $143.50 smaller than a full-size pickup, you probably won’t be allowed to haul more than one half cubic yard Notes: of mixed concrete at a time. If this means you’ll • One person mixing concrete in a wheelbarrow or be making multiple trips, be sure to place your mortar box and working hard can expect to mix one entire order at once so you will be charged the 80-pound bag in about five minutes (or close to three discounted rate for larger orders. and a half hours per cubic yard if mixing nonstop). If • Freshly mixed concrete is bounced and vibrated in you are pouring footings or if your project is broken the trailer as it rolls along over the road. A concrete up into smaller sections, you may be able to mix the mixer on board a concrete truck turns continually, concrete by hand, especially if you halve the mixing so road vibration does not create a problem. But time by recruiting a helper and an extra wheelbarrow. in a trailer, separation of the liquid and the heavier But for large slabs and walls, hand mixing is too slow. solids will occur during transport, weakening the You will not get consistency of water content, which concrete. If you need to haul the concrete more can lead to cracking along seams between batches. than 10 or 15 miles, a trailer is not recommended. Tooling also works better if you can finish the whole project at one time. • Electric or gas-powered mixers do save a lot of READYMIX CONCRETE (DELIVERED) time. A larger gas-powered mixer that can handle Delivery Charge: $100 to $150 on average three 80-pound bags will yield two cubic feet of Cost of 1 cubic yard: $90 mixed concrete in about five minutes. Total cost: $240 (per-yard cost drops off dramatically • General-purpose concrete (usually around 3,500 for larger orders) psi) is relatively inexpensive in bagged form, but Notes: • Operator charges: Concrete supplier may add additional charge for driver time beyond a minimum allowance of free time (5 or 10 minutes per yard is typical) • Customizing your concrete with admixtures such as air entrainers and accelerants usually doesn’t have a major impact on the cost of ready mix, as it does with bagged mixtures. Adding tint to the mixture can result in a surcharge of 50 percent or more, however. • Some drivers are happy to jump in and lend a hand with the work. Others prefer to stay in their climate-controlled cabs. If you get lucky, that’s great—but don’t plan on it.
Poured Concrete ■ 27■ Mixing Concrete When mixing concrete on site, purchase bags of dry premixed concrete and simply add water. Follow the Tools & Materials ▸ instructions carefully and take note of exactly how much water you add so the concrete will be uniform from one Power mixer or Bagged concrete mix batch to the next. Never mix less than a full bag, however, mortar box Clean, fresh water since key ingredients may have settled to the bottom. Wheelbarrow Mason’s trowel For smaller projects, mix the concrete in a Masonry hoe wheelbarrow or mortar box. For larger projects, rent or 5-gal. Bucket buy a power mixer. Be aware that most power mixers Safety glasses should not be filled more than half full. Gloves When mixing concrete, the more water you add, Particle mask the weaker the concrete will become. For example, if Hammer you need “slippery” concrete to get into the corners of 2 × 4 lumber a form, add a latex bonding agent or acrylic fortifier instead of water. Mix the concrete only until all of the dry ingredients are moistened; don’t overwork it.
Too dry
Too wet CorrectA good mixture is crucial to any successful concrete project. Properly mixed concrete is damp enough to form in your hand when you squeeze and dry enough to hold its shape. If the mixture is too dry, the aggregate will be difficult to work and will not smooth out easily to produce an even, finished appearance. A wet mixture will slide off the trowel and may cause cracking and other defects in the finished surface.
28 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Mix Concrete 1 2
Empty premixed concrete bags into a mortar box or Work the material with a hoe, continuing to add water until wheelbarrow. Form a hollow in the mound of dry mix, and then a pancake batter consistency is achieved. Clear out any dry pour water into the hollow. Start with 3⁄4 of the estimated water pockets from the corners. Do not overwork the mix. Also, keep amount per 80-lb. bag. track of how much water you use in the first batch so you will have a reliable guideline for subsequent batches.
■ Using a Power Mixer Eye protection
Particle mask or
half-mask respiratorFill a bucket with 3⁄4 gal. of water for each 80-lb. bag of Add all of the dry ingredients, and then mix for 1 minute. concrete you will use in the batch for most power mixers, 3 Pour in water as needed until the proper consistency is bags is a workable amount. Pour in half the water. Before you achieved and mix for 3 to 5 minutes. Pivot the mixing drum start power-mixing, carefully review the operating instructions to empty the concrete into a wheelbarrow. Rinse out the for the mixer. drum immediately.
Poured Concrete ■ 29■ Placing Concrete Placing concrete involves pouring it into forms, and then leveling and smoothing it with special masonry tools. Once the surface is smooth and level, control joints are cut and the edges are rounded. Special attention to detail in these steps will result in a professional appearance. Note: If you plan to add a special finish, read “Curing & Finishing Concrete” (page 34) before you begin your project. Be sure to apply a release agent before pouring the concrete.
Tools & Materials ▸
Wheelbarrow Masonry hoe
Shovel Mixed concrete
Lumber Spade
3" screws Hammer
Rebar Concrete vibrator
Sand Float
Moving concrete from the source to the destination
Bucket Groover
represents much of the work in many concrete pours. Make
Gloves Edger sure to plan ahead to create access for wheelbarrows or
Safety glasses ready-mix trucks, and get all of the help you can round up for
the actual pour.Do not overload your wheelbarrow. Experiment with sand Lay planks over the forms to make a ramp for the or dry mix to find a comfortable, controllable volume. This also wheelbarrow. Avoid disturbing the building site by using ramp helps you get a feel for how many wheelbarrow loads it will supports. Make sure you have a flat, stable surface between take to complete your project. the concrete source and the forms.
30 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Place Concrete 1 2
Load the wheelbarrow with fresh concrete. Clear a path Pour concrete in evenly spaced loads. Start at the farthest from the source to the site. Always load wheelbarrows from point from the concrete source, and work your way back. Pour the front; loading from the side can cause tipping. so concrete is a few inches above the tops of the forms. If you’re using wood scrap as shims to support a ramp end, be sure and fasten them together with screws or nails.
3 4
Continue placing concrete, working away from your Distribute concrete evenly in the project area using a masonry starting point. Do not pour more concrete than you can tool at hoe. Work the concrete with a hoe until it is fairly flat, and the one time. Monitor the concrete surface to make sure it does surface is slightly above the top of the forms. Remove excess not harden too much before you can start tooling. concrete from the project area with a shovel. Avoid overworking the concrete and take care not to disturb reinforcement.
(continued)
Poured Concrete ■ 31
5 6Work a spade blade between the inside edges of the forms Hammer the sides of forms to settle the concrete. This action and the concrete to remove trapped air bubbles that can draws finer aggregates in the concrete against the forms, weaken the material. This will help settle the concrete. creating a smoother surface on the sides. This is especially important when building steps. For larger pours, rent a concrete vibrator for this job (inset).
7 8Remove excess concrete with a screed board—a straight Float the surface in an arching motion once bleed water piece of 2 × 4 lumber or angle iron long enough to rest on disappears. Float with the leading edge of the tool tipped up, opposite forms. Move the board in a sawing motion, and keep and stop floating as soon as the surface is smooth so you do it flat as you work. If screeding leaves valleys in the surface, add not overwork the concrete. fresh concrete in the low areas and screed them to level.
32 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
9 Understanding Bleed Water ▸
Draw a groover tool at joint locations after bleed water has dried. Use a straight 2 × 4 as a guide. You may need to make several passes to create a smooth control joint. Avoid digging into the concrete surface with the flat edges of the tool. Smooth out tool marks with a float once the joint is cut.
Timing is key to an attractive concrete finish. When10 concrete is poured, the heavy materials gradually sink, leaving a thin layer of water—known as bleed water—on the surface. To achieve an attractive finish, it’s important to let bleed water evaporate before proceeding with other steps. Follow these rules to avoid problems:
• Settle and screed the concrete and add
control joints (steps 9 through 11) immediately
after pouring and before bleed water appears.
Otherwise, crazing, spalling, and other flaws
are likely.
• Let bleed water dry before floating or
edging. Concrete should be hard enough
that foot pressure leaves no more than a
1
⁄4"-deep impression.
• Do not overfloat the concrete; it may cause
bleed water to reappear. Stop floating if a
sheen appears and resume when it is gone.Shape concrete with an edging tool, smoothing between the Note: Bleed water may not appear with air-entrained forms and concrete to create a finished appearance. Make several concrete, which is used in regions where temperatures passes if necessary and use a float to smooth out any marks left by the groover or edger. Note: Cutting a radiused profile in the often fall below freezing. edges also prevents concrete from cracking and chipping.
Poured Concrete ■ 33■ Curing & Finishing Concrete Concrete that is exposed, such as for patios and of times a day to slow down the process. Concrete that sidewalks, requires a good finish for project success. dries too fast can crack. However, most professionals Creating the final finish may be as simple as troweling today have recognized that covering the concrete often the surface and letting it dry. Or, you may choose causes more problems than it prevents. So they are less to do something a little more decorative, such as an likely to cover the concrete, preferring instead to treat it acid stain, a broomed antiskid surface, or exposed with a curing or sealing agent once it sets up, or simply aggregate. Some of the fancier finishes you can do to let it dry naturally in the open air. with concrete are covered in the Decorative Masonry Finishing chapter. Because it is done when the concrete is still wet, we’ve included some information on exposed aggregate finishes here. Tools & Materials ▸ Once the fresh concrete has been edged and the control joints have been cut, it needs to dry for a period Broom Plastic sheeting of time before any surface finishing, such as brooming Wheelbarrow Aggregate or exposing aggregate, can be done. After that, it should Shovel Water dry overnight before any forms are removed. Finally, Magnesium float 2 × 4 lumber it should cure for three to seven days, or even longer Groover Screed board depending on the type of concrete, the conditions, Edger Muriatic acid and the nature of the project. Traditionally, concrete is Hose Work gloves and covered with burlap or sheet plastic for the drying and Coarse brush eye protection curing phases, and the surface is dampened a couple
Tip for a Broomed Finish ▸
For a nonslip finish, tool the concrete and then draw a clean stiff-bristle broom across the surface once the concrete is
thumbprint hard. Wait until concrete is firm to the touch to achieve a finer texture and a more weather-resistant surface.
Make sure all strokes are made in the same direction and avoid overlapping.34 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Create an Exposed Aggregate Finish Exposed aggregate finishes provide a rugged, nonskid into a landscape featuring natural stone. Chose from surface that is resistant to heavy traffic and extreme a wide variety of decorative aggregate to achieve weather. This effect helps the concrete surface blend different finishes.
1 2
Place the concrete. After smoothing the surface with a Pat the aggregate down with the screed board, and then screed board, let any bleed water disappear; then spread float the surface with a magnesium float until a thin layer of clean, washed aggregate evenly with a shovel or by hand. concrete covers the stones. Do not overfloat. If bleed water Spread smaller aggregate (up to 1” in dia.) in a single layer; for appears, stop floating and let it dry before completing the step. larger aggregate, maintain a separation between stones that is If you are seeding a large area, cover it with plastic to keep the roughly equal to the size of one stone. concrete from hardening too quickly.
3 4
Cut control joints and tool the edges. Let concrete set for 30 Rinse the concrete surface with a hose after it has cured to 60 minutes, and then mist a section of the surface and scrub for one week and covering is removed. If a residue remains, try with a brush to remove the concrete covering the aggregate. If scrubbing it clean. If scrubbing is ineffective, wash the surface brushing dislodges some of the stones, reset them and try again with a muriatic acid solution, and then rinse immediately and later. When you can scrub without dislodging stones, mist and thoroughly with water. scrub the entire surface to expose the aggregate. Rinse clean. Do not let the concrete dry too long, or it will be difficult to scrub off.
Poured Concrete ■ 35Preparing a Project Site The first stage of any poured concrete project is to Proper site preparation depends on the project and prepare the project site. The basic steps include site. Plan on a sub-base of compactible gravel. Some the following: projects require footings that extend past the frost line, while others, such as sidewalks, do not. Consult your
-
Lay out the project using stakes and strings. local building inspector about the specific requirements
-
Clear the project area and remove the sod. of your project.
-
Excavate the site to allow for a sub-base and If your yard slopes more than one inch per foot, you footings (if necessary) and concrete. may need to add or remove soil to level the surface. A
-
Lay a sub-base for drainage and stability and landscape engineer or building inspector can advise you pour footings (if necessary). on how to prepare a sloping project site.
-
Build and install reinforced wood forms.
Tools & Materials ▸ Rope Sod cutter Drill Asphalt-impregnated Carpenter’s square Straightedge Lumber (2 × 4, 1 × 4) fiber board Hand maul Level 3” Screws Wood stakes Tape measure Wheelbarrow Compactable gravel Work gloves Mason’s string Shovel Vegetable oil Common nails Line level Hand tamper or commercial Spade Circular saw release agent
Good site preparation is one of the keys to a successful project. Patience and attention to detail when excavating, building forms, and establishing a sub-base help ensure that your finished project is level and stable and will last for many years.
36 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Prepare the Site 1 2
Measure the slope of the building site to determine if you need to do grading work Dig a test hole to the planned depth before you start your project. First, drive stakes at each end of the project area. so you can evaluate the soil conditions Attach a mason’s string between the stakes and use a line level to set it at level. and get a better idea of how easy the At each stake, measure from the string to the ground. The difference between the excavation will be. Sandy or loose measurements (in inches) divided by the distance between stakes (in feet) will give soil may require amending; consult a you the slope (in inches per foot). If the slope is greater than 1” per foot, you may landscape engineer. need to regrade the site.
3 4 Isolation joint
Shown cut away
Shown cut away
Compactable gravel sub-baseAdd a compactable gravel sub-base to provide a level, When pouring concrete next to structures, glue a stable foundation for the concrete. For most building projects, 1 ⁄2”-thick piece of asphalt-impregnated fiber board to the pour a layer of compactable gravel about 4 to 6” thick, and use adjoining structure to keep the concrete from bonding with a tamper to compress it to 4”. the structure. The board creates an isolation joint, allowing the structures to move independently and minimizing the risk of damage.
Poured Concrete ■ 37■ How to Lay Out & Excavate the Site 1 2
3 .ft.
4 ft.
5 ft.Lay out a rough project outline with a rope or hose. Use Connect the stakes with mason’s strings. The strings a carpenter’s square to set perpendicular lines. To create the should follow the actual project outlines. To make sure the actual layout, begin by driving wood stakes near each corner strings are square, use the 3-4-5 triangle method: Measure of the rough layout. The goal is to arrange the stakes so they and mark points 3 ft. out from one corner along one string are outside the actual project area, but in alignment with the and 4 ft. out along the intersecting string at the corner. borders of the project. Where possible, use two stakes set back Measure between the points, and adjust the positions of the 1 ft. from each corner, so strings intersect to mark each corner strings until the distance between the points is exactly 5 ft. (below). Note: In projects built next to permanent structures, A helper will make this easier. the structure will define one project side.
3 4
Line levelReset the stakes, if necessary, to conform to the positions of Attach a line level to one of the mason’s strings to use as a the squared strings. Check all corners with the 3-4-5 method, reference. Adjust the string up or down as necessary until it is and adjust until the entire project area is exactly square. This level. Adjust the other strings until they are level, making sure can be a lengthy process with plenty of trial and error, but it is that intersecting strings contact one another. This ensures that very important to the success of the project, especially if you they are all at the same height relative to ground level. plan to build on the concrete surface.
38 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
5 6 Level line
Slope lineShift mason’s strings on opposite sides of the project Start excavating by removing the sod. Use a sod cutter if downward on their stakes (the lower end should be farther you wish to reuse the sod elsewhere in your yard (lay the sod away from the house). Most concrete surfaces should have as soon as possible). Otherwise, use a square-end spade to a slight slope to direct water runoff, especially if the surface cut away sod. Strip off the sod at least 6” beyond the mason’s is near your house. To create a standard slope of 1⁄8” per foot, strings to make room for 2 × 4 forms. You may need to remove multiply the distance between the stakes on one side (in feet) the strings temporarily for this step. by 1⁄8. For example, if the stakes were 10 ft. apart, the result would be 10⁄8 (11⁄4”). You would move the strings down 11⁄4” on the stakes on the low ends.
7 8
Make a story pole as a guide for excavating the site. First, measure down to ground Lay a sub-base for the project (unless level from the high end of a slope line. Add 71⁄2” to that distance (4” for the sub- your project requires a frost footing). Pour base material and 31⁄2” for the concrete if you are using 2 × 4 forms). Mark the total a 5”-thick layer of compactable gravel in distance on the story pole, measuring from one end. Remove soil from the site with a the project site, and tamp until the gravel spade. Use the story pole to make sure the bottom of the site is consistent (the same is even and compressed to 4” in depth. distance from the slope line at all points) as you dig. Check points at the center of the Note: The sub-base should extend at site using a straightedge and a level placed on top of the soil. least 6” beyond the project outline.
Poured Concrete ■ 39■ How to Build & Install Wood Forms 1 2 3
A form is a frame, usually made from Use the mason’s strings that outline Cut several pieces of 2 × 4 at least 2 × 4 lumber, laid around a project the project as a reference for setting 12” long to use as stakes. Trim one end site to contain poured concrete and form boards in place. Starting with the of each stake to a sharp point. Drive the establish its thickness. Cut 2 × 4s to longest form board, position the boards stakes at 3-ft. intervals at the outside create a frame with inside dimensions so the inside edges are directly below edges of the form boards, positioned to equal to the total size of the project. the strings. support any joints in the form boards.
4 5Drive 3” deck screws through the stakes and into the form Once the forms are staked and leveled, drive 3” deck board on one side. Set a level so it spans the staked side of screws at the corners. Coat the insides of the forms with the form and the opposite form board, and use the level as a vegetable oil or a commercial release agent so concrete won’t guide as you stake the second form board so it is level with the bond to them. Tip: Tack nails to the outsides of the forms to first. For large projects, use the mason’s strings as the primary mark locations for control joints at intervals roughly 11⁄2 times guide for setting the height of all form boards. the slab’s width (but no more than 30 times its thickness).
40 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Variations for Building Forms ▸ Straight forms made from dimensional lumber do not standard wood forms for the tops of footings for building work for every concrete project. Use ⁄4”-thick plywood 3 with brick or block when the footing will be visible. for building taller forms for projects such as concrete Create curves with hardboard, siding or other thin, steps or walls. Use the earth as a form when building flexible sheet stock attached at the inside corners of a footings for poured concrete building projects. Use form frame.
Braces
1
⁄ 8" hardboardTips for Working with Rebar & Remesh ▸
Cut rebar with a reciprocating saw Overlap joints in rebar by at least Leave at least 1” of clearance that is equipped with a metal-cutting 12”, and then bind the ends together between the forms and the edges blade (cutting rebar with a hacksaw with heavy-gauge wire. Overlap or ends of metal reinforcement. Use can take 5 to 10 minutes per cut). seams in wire mesh reinforcement bolsters or small chunks of concrete Use bolt cutters to cut wire mesh. by 12”. to raise remesh reinforcement off the sub-base, but make sure it is at least 2” below the tops of the forms.
Poured Concrete ■ 41Setting Concrete Posts
E ven among professional landscapers, you’ll find widely differing practices for setting fence posts. Some take the always-overbuild approach don’t bother. The posts may be set all at once, prior to installing the stringers and siding; or, they may be set one-at-a-time in a build-as-you-go approach. and set every post in concrete that extends a foot Ultimately, the decision of whether to set posts in past the frost line. Others prefer the adjustability concrete comes down to weight of the panels, as and improved drainage you get when setting posts well as where they fall in the fence layout. At the in packed sand or gravel. Some treat the post ends very least, gate posts and corner posts should be set with preservative before setting the posts, others into concrete.
Tools & Materials ▸
Shovel Post lumber (4 × 4)
Posthole digger or 2 × 4 lumber
gas-powered auger Screws
Digging bar auger Wood sealer
Tube form Hand tamper (for wood posts)
Saw Plumb bob
Width = 3x Drill Mason’s string
post size
Maul Paint brush
6" gravel Level Waxed paper
layer for Gravel
1 1
drainage Trowel Gloves and eyeDepth = ⁄ 3 – ⁄ 2 Option for sandy or of post height loose soil Gravel protection above ground Concrete mix
When setting posts for fences, one way to ensure that To preserve post ends, treat fence posts with wood post spacing is exactly correct is to assemble the fence panels preservative before setting them into the ground or into and posts prior to digging the postholes. Then, you can lay the concrete. These chemicals may be applied with a brush or, if fence section or sections in place and mark post locations you are setting a lot of posts, by dipping them directly into a exactly where the posts will hit. Level and brace the structure container. Most wood preservatives are quite toxic so follow all and fill in the concrete. safety precautions and handling recommendations.
42 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Set a Post in Concrete 1 2
Dig a hole that is three times wider Option: Use a gas-powered auger if Pour 6” of loose gravel into the than the post width (or diameter) and you are digging several postholes— bottom of the hole to create drainage. as deep as 1⁄3 the post length, plus 6”. especially if you need to dig deeper Tamp the gravel, using a hand tamper or Use a posthole digger for most of the than 20 to 24” (the depth at which wood post. digging and a digging bar to dislodge posthole diggers become ineffective). rocks and loosen compacted soil.
3 4
Set the post in the hole. Attach wood braces to two Mix all-purpose concrete and pour it into the hole, adjacent faces of the post. Check for plumb, then drive a overfilling it slightly. Tamp the concrete down with the butt stake into the ground near the end of each brace, and attach end of a 2 × 4 to settle it into the posthole. TIP: Mask the post the ends of the braces to the stakes. temporarily with waxed paper before adding concrete to protect the wood from discoloration and staining. Use a small trowel to smooth the concrete and form a slight crown.
Poured Concrete ■ 43Concrete Piers
C oncrete pier footings support the weight of outdoor structures, such as decks and pergolas. Check local codes to determine the size and depth Tools & Materials ▸ of pier footings required in your area. In cold Power auger or Concrete tube forms climates, footings must be deeper than the soil posthole digger Concrete mix frost line. Tape measure J-bolts or masonry To help protect posts from water damage, each Shovel anchors footing should be poured so that it is 2” above ground Reciprocating saw Scrap 2 × 4 level. Tube-shaped forms let you extend the footings or handsaw Gravel above ground level. Torpedo level Speed square As an alternative to inserting J-bolts into wet Hoe Shop vac concrete, you can use masonry anchors or install anchor Trowel Masking tape bolts with an epoxy designed for masonry installations. Hammer drill Epoxy Before digging, consult local utilities for the Shovel Gloves and eye location of any underground electrical, telephone, or Utility knife protection water lines that might interfere with footings. Wheelbarrow
■ How to Pour Concrete Piers 1 2 3
To install tube forms for concrete Slowly pour concrete into the tube, Level the concrete by pulling a wood piers, dig holes with a posthole digger guiding concrete from the wheelbarrow scrap across the top of the tube form or power auger. Pour 4 to 6” of gravel with a shovel. Fill about half of the form. using a sawing motion. Add concrete to in the bottom for drainage, and then Use a long board to tamp the concrete, any low spots. cut and insert the tube, leaving about filling any air gaps in the footing. Then 2” of tube above ground level. Pack soil finish pouring and tamping concrete around tubes to hold them in place. into the form.
44 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
4 5
Insert a J-bolt into wet cement, lowering it slowly and wiggling Use a torpedo level to make sure the J-bolt is plumb. If it slightly to eliminate any air gaps. Set the J-bolt so 3⁄4 to 1” is necessary, adjust the bolt and repack concrete. Let concrete exposed above the concrete. Brush away any wet concrete on dry, and then cut away exposed portion of tube with a utility the bolt threads. knife (optional).
■ How to Install Anchor Bolts in Epoxy 1 2
Drill a hole for the threaded rod after the pier has cured Wrap masking tape around 3⁄4 to 1” of rod for reference. at least 48 hours. Locate the bolt locations and drill using a Inject epoxy into hole using the mixing syringe provided by hammer drill and masonry bit sized to match the rod diameter. the manufacturer. Use enough epoxy so a small amount is Use a speed square to vertically align the drill, set the depth forced from the hole when the rod is fully inserted. Insert gauge so the rod will protrude 3⁄4 to 1” above the pier. After the rod immediately; epoxy begins to harden as soon as it is drilling, clean out debris from the hole using a shop vac. injected. Check the height of the rod, and then allow the epoxy to cure for 16 to 24 hours. If necessary, trim the rod using a reciprocating saw with a metal-cutting blade.
Poured Concrete ■ 45Poured Footings for Freestanding Walls
F ootings provide a stable, level base for brick, block, stone, and poured concrete structures. They distribute the weight of the structure evenly, prevent Tips for Planning ▸ • Describe the proposed structure to your local sinking, and keep structures from moving during building inspector to find out whether it requires seasonal freeze-thaw cycles. a footing and whether the footing needs The required depth of a footing is usually reinforcement. In some cases, 8”-thick slab determined by the frost line, which varies by region. footings can be used as long as the sub-base The frost line is the point nearest ground level where provides plenty of drainage. the soil does not freeze. In colder climates, it is likely • Keep footings separate from adjoining structures to be 48 inches or deeper. Frost footings (footings by installing an isolation board (page 37). designed to keep structures from moving during • For smaller poured concrete projects, consider freezing temperatures) should extend 12 inches below pouring the footing and the structure as one unit. the frost line. Your local building inspector can tell you • A multi-wall project such as a barbecue may the frost line depth for your area. require a floating footing (page 147).
Footings are required by building
code for concrete, stone, brick, and block
structures that adjoin other permanent
structures or that exceed the height
specified by local codes. Frost footings
extend 8 to 12" below the frost line. Slab
footings, which are typically 8" thick, may
be recommended for low, freestanding
structures built using mortar or poured
concrete. Before starting your project,
ask a building inspector about footing
recommendations and requirements for
your area.
Tools & Materials ▸
Rope Sod cutter Float Vegetable oil
Carpenter’s square Straightedge Drill or release agent
Hand maul Level Concrete mix Stakes
Tape measure Wheelbarrow #3 rebar Tie-rods
Mason’s string Hand tamper 16-gauge wire Eye protetction and
Line level Circular saw 2 × 4 lumber work gloves
Spade Reciprocating saw 3" screws
Shovel Isolation board Compactable gravel46 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Options for Forming Footings W hen you build footings, make them twice as wide as the wall or structure they will support. Footings also should extend at least 12 inches past will be pouring concrete over the footing. After the concrete sets up, press 12-inch pieces of rebar six inches into the concrete. The tie-rods will anchor the the ends of the project area. Add two tie rods if you footing to the structure it supports.
Sod removed
during construction
2 × 4 forms
Earth forms
Frost line Frost line
Shown cut away Shown cut awayFor poured concrete, use the earth as a form. Strip sod from For brick, block, and stone, build level, recessed wood around the project area, and then strike off the concrete with forms. Rest the screed board on the frames when you strike a screed board resting on the earth at the edges of the top of off the concrete to create a flat, even surface for stacking the trench. masonry units.
Wall
Wall width × 2
Add tie-rods
Shown cut awayMake footings twice as wide as the wall or structure they Add tie-rods if you will be pouring concrete over the footing. will support. They also should extend at least 12” past the ends After the concrete sets up, press 12” sections of rebar 6” of the project area. into the concrete. The tie-rods will anchor the footing to the structure it supports.
Poured Concrete ■ 47■ How to Pour a Footing 1 2
Make a rough outline of the footing using a rope or hose. Strip away sod 6” outside the project area on all sides and Outline the project area with stakes and mason’s string. then excavate the trench for the footing to a depth 12” below the frost line.
3Build and install a 2 × 4 form frame for the footing, aligning Option: Cut an isolation board and glue it to the existing it with the mason’s strings. Stake the form in place and adjust concrete structures at the point where they meet the new to level. sidewalk. Steps, foundation walls, driveways, and old sidewalk sections are examples of structures you’ll need to isolate from the new concrete.
48 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
4
Make two #3 rebar grids to reinforce the footing. For each grid, cut two pieces of #3 rebar 8” shorter than the length of the footing and two pieces 4” shorter than the depth of the footing. Bind the pieces together with 16-gauge wire, forming a rectangle. Set the rebar grids upright in the trench, leaving 4” of space between the grids and the walls of the trench. Coat the inside edge of the form with vegetable oil or commercial release agent.
5 6
Mix and pour concrete, so it reaches Cure the concrete for one week before you build on the footing. Remove the forms the tops of the forms. Screed the surface and backfill around the edges of the footing. using a 2 × 4. Float the concrete until it is smooth and level.
Poured Concrete ■ 49Poured Concrete Walkway
I f you’ve always wanted to try your hand at creating with concrete, an outdoor walkway is a great project to start with. The basic elements and construction Tools & Materials ▸ steps of a walkway are similar to those of a poured Drill, bits Drywall screws concrete patio or other landscape slab, but the Circular saw (21⁄2, 31⁄2”) smaller scale of a walkway makes it a much more Sledgehammer 4” wood or deck manageable project for first-timers. Placing the wet Mason’s string screws concrete goes faster and you can easily reach the Line level Compactable gravel center of the surface for finishing from either side of Excavation tools (3⁄4” maximum the walkway. Bow rake stone size) Like a patio slab, a poured concrete walkway 2- or 4-ft. level 6 × 6” welded also makes a good foundation for mortared surface Duct tape wire mesh materials, such as pavers, stone, and tile. If that’s Plate compactor or Metal rebar your goal, be sure to account for the thickness of the hand tamp Tie wire surface material when planning and laying out the Heavy-duty wire or 2” wire bolsters walkway height. A coarse broomed or scratched finish bolt cutters Isolation board and on the concrete will help create a strong bond with the Concrete mixing construction mortar bed of the surface material. tools adhesive The walkway in this project is a four-inch-thick Shovel Concrete form by 26-inch-wide concrete slab with a relatively Hammer release agent fine broom finish for providing slip resistance in Magnesium float 4,000 psi concrete wet weather. It consists of two straight, 12-foot- Edger (or as required by long runs connected by a 90-degree elbow. After 1” groover local code) curing, the walkway can be left bare for a classic, Trowel Clear polyethylene low-maintenance surface, or it can be colored with Push broom sheeting a permanent acid stain, and can be sealed or left Lumber (2 × 2, Eye and ear unsealed, as desired. When planning your walkway 2 × 4) protection project, consult your city’s building department for 7 ⁄16” hardboard siding Sprayer recommendations and construction requirements. or 1⁄4” lauan for Work gloves curved forms
Poured concrete walkways can be
designed with straight lines, curves, or
sharp angles. The flat, hardwearing surface
is ideal for frequently traveled paths and
will stand up to heavy equipment and
decades of snow shoveling.50 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Options for Sloping a Walkway 1 2×4 1 ⁄4” spacer 4” deck screws ⁄4” spacer (set on edge)
Curved screed board 2×2
Level line
Slope line
( 1⁄4" per foot)
2 × 4 formsStraight slope: Set the concrete form Crowned slope: When a walkway does not run near the house foundation, you lower on one side of the walkway so have the option of crowning the surface so it slopes down to both sides. To make the the finished surface is flat and slopes crown, construct a curved screed board by cutting a 2 × 2 and 2 × 4 long enough to downward at a rate of 1⁄4” per foot. rest on both sides of the concrete form. Sandwich the boards together with a 1⁄4”-thick Always slope the surface away from the spacer at each end, and then fasten the assembly with 4” wood or deck screws house foundation or, when not near the driven at the center and the ends. Use the board to screed the concrete (see step 7, house, toward the area best suited to page 32). accept water runoff.
■ Options for Reinforcing a Walkway
As an alternative to the wire mesh reinforcement used in the following project, you can reinforce a walkway slab with metal rebar (check with the local building code requirements). For a 3-ft.-wide walkway, lay two sections of #3 rebar spaced evenly inside the concrete form. Bend the rebar as needed to follow curves or angles. Overlap pieces by 12” and tie them together with tie wire. Use wire bolsters to suspend the bar in the middle of the slab’s thickness.
Poured Concrete ■ 51■ How to Build a Concrete Walkway 1
Lay out the precise edges of the finished walkway using stakes (or batterboards) and mason’s string (see pages 38 to 39 for additional help with setting up and using layout strings). Where possible, set stakes 12” or so outside of the walkway edges so they’re out of the way. Make sure any 90° corners are square using the 3-4-5 measuring technique. Level the strings, and then lower the strings on one side of the layout to create a downward slope of 1⁄4” per foot (if the walkway will be crowned instead of sloped to one side, keep all strings level with one another: see page 39). Begin the excavation by cutting away the sod or other plantings 6” beyond the layout lines on all sides of the site.
2 3Excavate the site for a 6”-thick gravel sub-base, plus any sub- Cover the site with a 4” layer of compactable gravel, grade (below ground level) portion of the slab, as desired. Measure and then tamp it thoroughly with a plate compactor. Add 4” the depth with a story pole against the high-side layout strings, or more of gravel and screed the surface flat, checking with a and then use a slope gauge to grade the slope. Tamp the soil slope gauge to set the proper grade. Compact the gravel so the thoroughly with a plate compactor. top surface is 4” below the finished walkway height. Reset the layout strings at the precise height of the finished walkway.
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4 5
Build the concrete form with straight 2 × 4 lumber so the Add curved strips made from hardboard or lauan to create inside faces of the form are aligned with the strings. Fasten the curved corners, if desired. Secure curved strips by screwing form boards together with 3 1⁄2” screws. Drive 2 × 4 stakes for them to wood stakes. Recheck the gravel bed inside the reinforcement behind butt joints. Align the form with the layout concrete form, making sure it is smooth and properly sloped. strings, and then drive stakes at each corner and every 2 to 3 ft. in between. Fasten the form to the stakes so the top inside corners of the form boards are just touching the layout strings. The tops of the stakes should be just below the tops of the form.
6 7
Lay reinforcing wire mesh over the gravel base, keeping the Place the concrete, starting at the far end of the walkway. edges 1 to 2” from the insides of the form. Overlap the mesh strips Distribute it around the form (don’t throw it) with a shovel. by 6” (one square) and tie them together with tie wire. Prop up the As you fill, stab into the concrete with the shovel, and tap a mesh on 2” wire bolsters (“chairs”) placed every few feet and tied hammer against the back sides of the form to eliminate air to the mesh with wire. Install isolation board (see page 37) where pockets. Continue until the form is evenly filled, slightly above the walkway adjoins other slabs or structures. When you’re ready the tops of the form. for the concrete pour, coat the insides of the form with a release agent or vegetable oil.
(continued)
Poured Concrete ■ 53
8Immediately screed the surface with a straight 2 × 4: Two people pull the board Option: Cut an isolation board and glue backward in a side-to-side sawing motion, with the board resting on top of the form. As it to the existing concrete structures you work, shovel in extra concrete to fill low spots or remove concrete from high spots, at the point where they meet the new and re-screed. The goal is to create a flat surface that’s level with the top of the form. sidewalk. Steps, foundation walls, driveways, and old sidewalk sections are examples of structures you’ll need to isolate from the new concrete.
9 10Float the concrete surface with a magnesium float, working Use an edger to shape the side edges of the walkway back and forth in broad arching strokes. Tip up the leading edge of along the wood form. Carefully run the edger back and forth the tool slightly to prevent gouging. Stop floating once the surface along the form to create a smooth, rounded corner, lifting the is relatively smooth and has a wet sheen. Be careful not to over- leading edge of the tool slightly to prevent gouging. float, indicated by water pooling on the surface. Allow the bleed water to disappear and the concrete to harden sufficiently (see page 33).
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11 12
Mark the locations of the control joints onto the top edges Cut the control joints with a 1” groover guided by a straight of the form boards, spacing the joints 11⁄2 times the width of 2 × 4 held (or fastened) across the form at the marked the walkway. locations. Make several light passes back and forth until the groove reaches full depth, lifting the leading edge of the tool to prevent gouging. Remove the guide board once each joint is complete. Smooth out the tool marks with a trowel or float.
13 14
Create a nonslip surface with a broom. Starting at the far Cure the concrete by misting the walkway with water, and side edge of the walkway, steadily drag a broom backward over then covering it with clear polyethylene sheeting. Smooth out the surface in a straight line, using a single pulling motion. Repeat any air pockets (which can cause discoloration), and weight in single, parallel passes (with minimal or no overlap), and rinse down the sheeting along the edges. Mist the surface and off the broom bristles after each pass. The stiffer and coarser the reapply the plastic daily for a few days. broom, the rougher the texture will be.
Poured Concrete ■ 55Concrete Steps Tools & Materials ▸ Tape measure Bolsters Sledge hammer Construction adhesive D esigning steps requires some calculations and some trial and error. As long as the design meets safety guidelines, you can adjust elements such as Shovel Drill Compactable gravel Concrete mix the landing depth and the dimensions of the steps. Reciprocating saw Fill material Sketching your plan on paper will make the job easier. Level Exterior-grade 3⁄4” The single-wall plywood forms seen here are sufficient Mason’s string plywood for stairs of this size, but if the scale of your project is Hand tamper 2” deck screws larger, add a second layer to each side prevent bowing Mallet Isolation board or blow-out. Concrete mixing tools #3 rebar Before demolishing your old steps, measure them Jigsaw Stakes to see if they meet safety guidelines. If so, you can Clamps Latex caulk use them as a reference for your new steps. If not, Ruler or framing square Vegetable oil or start from scratch so your new steps do not repeat any Float commercial design errors. Step edger release agent For steps with more than two risers, you’ll need Broom Eye protection and to install a handrail. Ask a building inspector about 2 × 4 lumber gloves other requirements. Steel rebar grid J-bolts Wire Concrete sealer
New concrete steps give a fresh, clean appearance to your house. And if your old steps are unstable, replacing them with concrete steps that have a non-skid surface will create a safer living environment.
56 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Design Steps 1 2
Overall run
Overall riseAttach a mason’s string to the house foundation, 1” below Measure down from the string to the bottom of the stake the bottom of the door threshold. Drive a stake where you to determine the overall height, or rise, of the steps. Divide want the base of the bottom step to fall. Attach the other the overall rise by the estimated number of steps. The rise of end of the string to the stake and use a line level to level it. each step should be between 6” and 8”. For example, if the Measure the length of the string—this distance is the overall overall rise is 21” and you plan to build three steps, the rise of depth, or run, of the steps. each step would be 7” (21 divided by 3), which falls within the recommended safety range for riser height.
3 4 Landing depth minimum = door + 12” Riser height
6" – 8" Tread depth
Overall rise
10" – 12"
Minimumlanding depth 12” Overall run
Measure the width of your door Sketch a detailed plan for the steps, keeping these guidelines in mind: Each step and add at least 12”; this number is the should be 10 to 12” deep, with a riser height between 6 and 8”, and the landing minimum depth you should plan for the should be at least 12” deeper than the swing radius (width) of your door. Adjust the landing area of the steps. The landing parts of the steps as needed, but stay within the given ranges. Creating a final sketch depth plus the depth of each step will take time, but it is worth doing carefully. should fit within the overall run of the steps. If necessary, you can increase the overall run by moving the stake at the planned base of the steps away from the house, or by increasing the depth of the landing.
Poured Concrete ■ 57■ How to Build Concrete Steps 2 1 Isolation board
Remove existing steps; if the old steps are concrete, break Dig 12”-wide trenches to the required depth for footings. them up and set aside the rubble to use as fill material for the Locate the trenches perpendicular to the foundation, spaced new steps. Wear protective gear, including eye protection and so the footings will extend 3” beyond the outside edges of gloves, when demolishing concrete. Tip: A rental jackhammer the steps. Install rebar grids (page 59) for reinforcement. Affix can shave hours of hard labor from demolishing concrete steps. isolation boards to the foundation wall inside each trench using a few dabs of construction adhesive (12” below the permanent frost line).
3 4 5Mix the concrete and pour the When bleed water disappears, Let the footings dry for two days, and footings. Level and smooth the concrete insert 12” pieces of rebar 6” into the then excavate the area between them with a screed board. You do not need to concrete, spaced at 12” intervals and to 4” deep. Pour in a 5”-thick layer of float the surface afterwards. centered side to side. Leave 1 ft. of clear compactable gravel sub-base and tamp space at each end. until it is level with the footings.
58 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
6 7
Bevel
Make slopes 1⁄ 8" per footTransfer the measurements for the side forms from your working sketch onto 3⁄4” Cut form boards for the risers to fit exterior-grade plywood. Cut out the forms along the cutting lines using a jigsaw. Save between the side forms. Bevel the bottom time by clamping two pieces of plywood together and cutting both side forms at the edges of the boards when cutting to same time. Add a 1⁄8” per foot back-to-front slope to the landing part of the form. create clearance for the float at the back edges of the steps. Attach the riser forms to the side forms with 2” deck screws.
8 Cleats 9
Riser
supportCut a 2 × 4 to make a center support for the riser forms. Use Cut an isolation board and glue it to the house foundation 2” deck screws to attach 2 × 4 cleats to the riser forms, and at the back of the project area. Set the form onto the footings, then attach the support to the cleats. Check to make sure all flush against the isolation board. Add 2 × 4 bracing arms to the corners are square. sides of the form, attaching them to cleats on the sides and to stakes driven into the ground.
(continued)
Poured Concrete ■ 59
10 11Fill the form with clean fill (broken concrete or rubble). Stack Lay pieces of #3 rebar on top of the fill at 12” intervals, and the fill carefully, keeping it 6” away from the sides, back, and attach them to bolsters with wire to keep them from moving top edges of the form. Shovel smaller fragments onto the pile when the concrete is poured. Keep rebar at least 2” below the to fill the void areas. This conserves new concrete. top of the forms. Mist the forms and the rubble with water.
12 13Coat the forms with vegetable oil or a release agent so concrete won’t stick to the Float the steps, working the front forms. Mix concrete and pour steps one at a time, beginning at the bottom. Settle and edge of the float underneath the smooth the concrete with a screed board. Press a piece of #3 rebar 1” down into the beveled edge at the bottom of each “nose” of each tread for reinforcement. riser form.
60 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
14 Shown cut away for clarity
Pour concrete into the forms for the remaining steps and Option: For railings with mounting plates that attach to sunken the landing. Press rebar into the nose of each step. Keep an J-bolts, install the bolts before the concrete sets (page 45). eye on the poured concrete as you work, and stop to float any Otherwise, choose railings with surface-mounted hardware concrete as soon as the bleed water disappears. (see step 16) that can be attached after the steps are completed.
15 16
Mounting
plateOnce the concrete sets, shape the Remove the forms as soon as the surface is firm to the touch, usually within steps and landing with an edger. Float the several hours. Smooth rough edges with a float. Add concrete to fill any holes. If forms surface. Finish by brushing with a stiff- are removed later, more patching may be required. Backfill the area around the base bristled broom for maximum traction. of the steps, and seal the concrete. Install a railing.
Poured Concrete ■ 61
The concrete steps seen here require enoughEntryway Steps concrete to make pouring them a fairly big undertaking, but because the structures they are integrated with are a retaining wall and a sandset
I ndoors or outdoors, steps undergo a lot of abuse. Everyday foot traffic, appliance moving, shoveling, and freeze/thaw cycles are just some of the stresses that can paver walkway, a full concrete footing that extends beyond the frost line is not required.
contribute to premature step failure. In short, you want steps to be durable. And when it comes to durability, poured concrete is virtually impossible to beat. Tools & Materials ▸ Building entryway steps can be a relatively simple Spud bar Edging tool landscaping project or it can be a fairly complex home Shovel Lumber (2 × 4, remodeling project involving structural engineers Circular saw 2 × 8) and building permits. The key variables are the total Power miter saw Deck screws height and whether or not the steps are connected Table saw Concrete release to a permanent structure with a frost footing. If your Drill/driver agent project is simply two or three concrete steps that Level #3 rebar solve a slope problem in your yard, the standards are Tamper Concrete relatively low and you can probably accomplish the Bow rake Sheet plastic project in an afternoon with a couple bags of concrete Wheelbarrow Sprayer mix and some gravel. But if your new concrete steps Float or trowel Concrete stain will include three or more risers and will serve as the Compactable gravel Eye protection and entryway to your house, then you are looking at a fairly Crushed rock work gloves major concrete project.
Poured concrete steps are hardworking structures that are at home in just about any setting. If they are freestanding (not attached to a house), they normally do not require a frost footing.
62 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Freestanding Stairs Form
2 × 4 nailer
2×8 2 × 4 brace
2 × 4 brace
Clean fill
2 × 4 stake
Compactable
gravelThe form for these stairs is built from 2 × 8 lumber, creating risers with a height of 71⁄4”—the actual width of a 2 × 8.
Poured Concrete ■ 63■ How to Pour Concrete Landscape Steps 1 2
Remove any old steps and prepare the building site. If Excavate for the new steps. If you are building next to the old steps are concrete, you’ll need to break them up first a house, you’ll need to dig down past the frost line to pour (see page 58). Wood steps, such as the railroad-tie steps seen footings. For larger steps you may find it worth your time to here, generally can be pried out with a sturdy spud bar. Note: rent a small backhoe or hire an excavation contractor to dig Before you do any digging, contact your local utilities to have out for the project. underground lines identified and flagged.
3 4Prepare a sturdy base for the structure by filling the bottom Create drainage by adding a 6 to 12” layer of 1 to 2”-dia. of the excavation area with a 4 to 6” layer of compactable gravel crushed rock on top of the compactable gravel. This type of and then compacting it with a hand tamper or gas-powered rock is not compactable, but you can settle it somewhat by plate vibrator. The base should extend at least 6” beyond the working it with a bow rake. area where the forms will be located.
64 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
5 6
Cut the form boards. Although 3⁄4” plywood is often used for Assemble the frames. Here, the form for the steps is being step forms (see pages 59 to 60), 2 × 8 stock is being used here to created by building and squaring four three-sided frames make the riser forms and the form sides. The 71⁄4” actual width of that are equal in width. The deepest frame is on the bottom, a 2 × 8 is perfect for an exterior step riser when coupled with an and the others, which decrease in length by 11” each, are 11” tread depth, and the beefy thickness of the dimensional stacked on top of it. When the squared 2 × 8 frames are bound lumber makes for a sturdier form that requires less reinforcement together, they will create the form. and is often easier to strip. To create nosing on the steps, cut a 1⁄2 × 11⁄2” rabbet along the top inside edge of each riser form (inset).
7 8 Riser brace
Attach 2 × 4 battens to the sides of the form once the frames Set the fully assembled form into the prepared step are squared, stacked, and pinned together with nails or screws. In construction area. You’ll need at least one helper for this. Add addition to binding the frames together, the battens will provide or remove gravel beneath the bottom of the form until the fastening surfaces for the braces that support the form. Attach bottom is at or slightly below grade. 2 × 4 riser braces to keep the riser boards from bowing outward.
(continued)
Poured Concrete ■ 65
9 10Level and brace the form with 2 × 4 braces that are attached Add clean fill inside the form. Chunks of old concrete are to stakes on one end and to the sides of the form battens on the perfect for this. The main reason for the clean fill is to conserve other end. Once the form is level and plumb, reset it so it slopes on the expense of fresh concrete, but it will also assist in drainage 1 ⁄8” per foot from the back edge of the top step to the bottom on and lower the likelihood of cracking. Once you have filled the form the lowest riser (inset). to within (but no closer than) 6” of any surface, dump crushed gravel onto the top of the pile and let it filter down to fill voids.
11 12Place reinforcement inside the form. Cut lengths of #3 rebar Begin filling the form with concrete, starting with the bottom about 8” shorter than the step width. Place the rebar strips on step. Work the concrete with the shovel to help settle out air top of the clean fill pile so the rocks hold them in place. Position bubbles and rap the form with a mallet for the same purpose. one length a couple of inches back from each crotch where a Tip: To assure best results, rent a concrete vibrator to settle the riser meets a tread. Also place a piece so it reinforces the front material into all the crevices and corners. Once you have filled of each tread, setting it 1” to 2” back and down from the corner. each step, immediately strike off the concrete with a float.
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13 14
Smooth the concrete surfaces once the steps are all filled, Profile the tread noses and sides with a concrete edging working a magnesium float or steel trowel back and forth to level tool. Set bolts or hardware for handrails, if required, into the the concrete as you smooth it. Let the concrete set until the bleed fresh concrete. You can also attach handrail hardware by water disappears. drilling holes after the concrete has set. For extra traction, broom the treads. Tack sheet plastic over the concrete and let it dry for at least two days.
15 16
Remove the forms and finish the steps if desired. Here, the Backfill around the edges of the steps and install or concrete has been colored with concrete stain and a coating of replace pathways and landings at the top and bottom of the penetrating concrete stain is being applied. Secure the handrail landscape steps. into the stanchions or hardware, if required. Once the coatings are dry, backfill around the steps.
Poured Concrete ■ 67Poured Concrete Slab
A slab foundation commonly used for garages or patios is called a slab-on-grade foundation. This combines a three and a half- to four-inch-thick floor The slab shown in this project has a three and one half-inch-thick interior with an eight-inch-wide by eight- inch-deep footing along the perimeter. The top of the slab with an 8- to 12-inch-thick perimeter footing that slab sits four inches above ground level (grade). There is provides extra support. The foundation can be poured a four-inch-thick layer of compacted gravel underneath at one time using a simple wood form. the slab, and the concrete is reinforced internally with a Because they sit above ground, slab-on-grade layer of six by six-inch welded wire mesh. foundations are susceptible to frost heave; in In some areas, you may be required to add more cold-weather climates they are suitable only for rebar in the perimeter. Check the local code. If this detached buildings. Specific design requirements foundation will be used as a garage surface, then set also vary by locality, so check with the local building 8-inch-long J-bolts into the slab along the edges, after department regarding the depth of the slab, the concrete is poured and finished. These J-bolts are metal reinforcement required, the type and amount used later to anchor the wall framing to a slab. If this of gravel required for the sub-base, and whether a foundation will serve as a patio sub-base, consider plastic or other type of moisture barrier is needed using one of the finishing techniques described on under the slab. pages 238 to 281.
Tools & Materials ▸
Work gloves and eye Long level Concrete edging tool Metal mending plates
protection Tape measure Wood or magnesium Rewire mesh
Stakes and boards Drill concrete float Concrete
Mason’s lines Wheelbarrow Paint roller J-bolts
Plumb bob Bull float Compactable gravel Concrete cure and seal
Shovel Concrete groover tool Lumber (2 × 4, 2 × 8) Plate compactor or
Tie wire Release agent 3" deck screws hand tamperA concrete slab with an adjoining concrete apron and driveway is the most common garage foundation setup. The same techniques in this project can be applied when pouring a patio or a foundation.
68 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Pour a Concrete Slab 1 String lines
2" slope toward door 4" concrete
for drainage 6 × 6" reinforcing mesh
Gravel
Hold-down bolts
To 6" below frost line, if requiredBegin to lay out the excavation with pairs of batterboards installed at each corner of the garage slab site. Position them about 2 ft. outside the perimeter of the slab area so you’ll have plenty of room to work. Run level mason’s lines between the batterboards to establish the final size of the slab. Drop a plumb bob down from the intersections of the strings and drive a stake at each corner.
2 3
Excavate the area about 2 ft. wider and longer than the staked Fill the excavation area with 4” of compactable gravel, size of the slab. The poured slab should slope slightly to facilitate letting it spill down into the 12”-deep footings that frame the drainage. Remove 3 to 4” of soil from the excavation area, and perimeter. Tamp the gravel level and smooth it with a plate dig a deeper trench around the perimeter for the footing. The compactor. The gravel surface should maintain the 2” total outside of the footing should line up with the mason’s lines. back-to-front slope. Depending on your soil conditions, some Slope the soil to create a transition between the excavated concrete contractors recommend laying 6-mil polyethylene interior and the footing. Check your local building codes to sheeting over the compacted base to form a moisture barrier. determine the correct footing size and depth for your climate Tip: Install electrical conduit underneath the slab if you will be and soil conditions. providing underground electrical service.
(continued)
Poured Concrete ■ 69
4 5Drive woods stakes along the outside of a form (built with Add rewire reinforcement according to the requirements in 2 × 4 lumber), placing stakes at 4-ft. intervals. Place two stakes your area. Here, rows of 6 × 6 wire mesh are set onto spacers at each corner. Set the tops of stakes flush with the top edges (chunks of brick) in the pour area. Overlap the sheets of mesh of the form (or slightly below the tops). As you drive in stakes, by 6” and stop the rows about 2” in from the insides of the form. periodically check the form to be sure it is level and measure Fasten the mesh together with tie wire. Apply a release agent. from corner to corner to ensure that it’s square. The form should measure 4” above grade. Attach stakes to the form with deck screws to hold it in place.
6 7Pour the concrete. Have ready-mix concrete delivered to Strike off the concrete once a section of a form is filled. The your job site and place it into the forms with wheelbarrows best way to do this is to have two helpers strike off (screed) and shovels (make sure to have plenty of help for this job). the wet concrete with a long 2 × 6 or 2 × 8 that spans the Fill a form with concrete, starting at one end. Use a shovel to width of the form. Drag the screed board back and forth along settle the concrete around the reinforcement and to remove the top of the form in a sawing motion to level and smooth air pockets. Fill the form to the top. Note: In most municipalities the concrete. Fill any voids ahead of the screed board with you must have the forms and sub-base inspected before the shovelfuls of concrete. concrete is poured.
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8 9
Smooth the surface further with a bull float as soon as Push J-bolts down into the concrete, wiggling them slightly to you’re finished screeding, working across the width of the slab. eliminate air pockets. Twist the bottom hooked ends so they face Floating forces aggregate down and draws sand and water to into the slab. Position the J-bolts 13⁄4” from the edges of the slab, the surface to begin the smoothing process. aligned with your layout marks. Leave 21⁄2” of bolt thread exposed, and make sure the J-bolts are plumb. Smooth the surrounding concrete with a wooden or magnesium concrete float.
10 11
Use a magnesium or wood hand-held float to refine the Apply a coat of cure and seal product (See Resources, page slab’s finished surface as soon as the bleed water evaporates. 313) to the surface once it dries so you do not have to water Work the float back and forth, starting from the middle of the the concrete surface during the curing stage. After a couple of slab and moving outward to the edges. Use large scraps of days, strip off the forms. Wait at least one more day before you 2”-thick rigid foam insulation as kneeling pads while you work. begin building on the slab.
Poured Concrete ■ 71The moldable nature of poured concrete makes it ideal for creating patios with curves and custom shapes in addition to perfect squares and rectangles.
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Round Patio
F ew outdoor surfaces are as heavy-duty as a properly poured concrete slab. As a patio material, poured concrete is tough to beat. The surface is flat, smooth, house with an isolation board and slope the surface so water drains away from the foundation. A smaller slab is much more manageable for amateurs. Larger slabs easy to clean, and fairly maintenance-free. A concrete often require that you place and tool the wet concrete slab is also the best foundation for decorative treatments in workable sections, and these steps must continue like mortared brick, tile, and stone. And if you like the simultaneously until the entire slab is filled and simplicity and durability of a bare concrete patio, but leveled before the concrete begins to set. Therefore, flat gray doesn’t suit your design scheme, you can always it’s a good idea to seek guidance and/or assistance apply an acid stain, dry pigment colors, or concrete paint from a concrete professional if your plans call for a (rated for exterior use) for custom coloring effects that large patio. don’t compromise the surface’s performance. Because they are permanent structures, concrete If you’ve never worked with poured concrete patios are often governed by local building codes and before, you’ll find that most of the time lies in preparing you might need a permit for your project—especially the site and building the forms for containing and if the patio abuts a permanent structure. Before you shaping the wet concrete. Once the concrete is mixed get started, contact your city’s building department or delivered to your site, time is of the essence, and to learn about permit requirements and general the best way to ensure quality results is to be prepared construction specifications in your area, including: with strong forms, the right tools, and an understanding of each step of the process. And it never hurts to have • Zoning restrictions help: You’ll need at least two hardworking assistants for • Depth of gravel sub-base the placing and finishing stages. • Concrete composition This patio project follows the steps for building a • Slab thickness and slope small (100 square feet or so) slab that can be poured • Internal reinforcement (wire mesh, and finished all at once. The patio featured here is rebar, etc.) a circular, freestanding structure slightly more than • Control joints (see page 35) 10 feet in diameter. If you are building a patio of any • Moisture barrier under slab (not a shape that abuts your house, always isolate it from the common requirement)
Forming Curves ▸
Creating a smooth curve in a concrete
form can be done by using one of
several different techniques. The
easiest and fastest is to rip-cut strips
of bendable sheet stock, such as
hardboard, lap siding (nonbeveled),
or thin plywood. Use 1⁄4 or 3⁄8"-thick
stock—thinner will flex too much
and thicker is difficult to bend. If you
need greater rigidity without giving
up flexibility, make a curved form by
cutting saw kerfs every inch or so
about halfway into a piece of 1 × 4.
For thicker slabs you may use a 1 × 6.
Poured Concrete ■ 73
Control joint
3 1⁄ 2 to 4" concrete
6 to 8" compactable
gravel
6×6 wire remesh
Bolster
7
⁄ 16"-thick
2×4 hardboard siding
stakeWell-constructed forms and properly prepared foundational elements will ensure your slab is structurally sound.
Tools & Materials ▸
Drill Lawn edger Bull float Isolation board
Circular saw Plumb bob Edger and construction
Hand maul or Plate compactor or 1" groover adhesive
sledgehammer hand tamper Magnesium trowel 4,000 psi concrete
Mason’s string Chalk line Fine-bristled push (or as required by
Stakes Hammer broom (optional) local code)
Marking paint 31⁄2" hardboard lap Lumber (1 × 2, 2 × 4) Sprayer
Line level siding Compactable gravel Clear polyethylene
Excavation tools Heavy-duty wire cutters Screws sheeting
Bow rake or bolt cutters 6 × 6" wire mesh Safety protection
Level Concrete mixing tools Tie wire (per manufacturer
Eye protection and Shovel or masonry hoe 2" wire bolsters recommendations)
gloves Wheelbarrow Release agent74 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build a Round Concrete Patio 1
Establish layout lines for the site excavation using batterboards, mason’s string, and inverted marking paint. Set the lines so they reach at least 12” beyond the work area on all sides. Eventually, the gravel base should extend 12” beyond the slab. Use two pairs of perpendicular batterboards with strings to establish the centerpoint of a round patio (where the strings intersect). To create a rough outline for the patio excavation, drive a stake at the centerpoint and then attach a string to the top of the stake. Tape the other end of the string to a can of inverted marking paint so the distance from the stake to the can equals the radius of the circle, including the gravel base; mark the outline.
2 3
Cut the sod on the perimeter of the excavation area to define Excavate the site for a 6- to 8”-thick compactable gravel where to dig. For better access, first remove the batterboards sub-base plus any subgrade (below ground level) portion of (or at least the strings). A lawn edger works well for cutting the the slab. If building next to your house, grade the soil so it outline into the sod (be sure to wear safety equipment). slopes away from the house at 1⁄8” per foot. Measure down from leveled cross strings with a story pole to gauge the depth as you work. Compact the soil after grading using a plate compactor or a hand tamper. (continued)
Poured Concrete ■ 75
Patio Next to a House ▸
If your patio will butt up to a
house or another permanent
structure, you should use the
ground level next to the house
as your starting point for
setting slope and establishing
a patio layout. Snap a
chalk line onto the house
foundation at the precise
elevation of the top of the
finished slab. This should be
1 to 3" below any patio door
threshold. You can use this
line for reference during the
site prep and concrete pour
and finishing.
4 5Fill the excavation area with a 4”-thick layer of compactable Use a plate compactor to tamp the first 4” of graded gravel. Use an upside-down bow or garden rake to move the compactable gravel. Add another 2 to 4” layer of gravel until rock around. Rake the rock until it is level and follows the the top surface is an inch or so above the finished level. Use grade of the soil base. cross strings and the story pole to make sure the sub-base is uniform and follows the 1⁄8” per ft. slope. Tamp until the gravel is compacted and at the correct height relative to your lines.
76 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
6
Set level lines for the form height. Replace batterboards and retie the mason’s lines so they are level and at the top height of the forms. If you are making a circular patio, as seen here, add intermediate stakes between the batterboards and tie lines to divide the circle into at least eight segments. Drop a plumb bob from the point where the lines intersect and drive a stake at this centerpoint. Use this stake to create a string compass and redraw the patio outline (inset, see step 1).
7 8 9
Drive stakes for anchoring the forms Install forms. Here, 7⁄16”-thick pieces of Drive stakes behind the forms around the perimeter of the patio, just hardboard lap siding have been rip-cut anywhere where the strips require outside the outline. Drive the stakes into 31⁄2” strips to make bendable forms. additional bending or anchoring to deep enough that they will be beneath Cut each strip long enough to span three follow the round outline. Attach the the tops of the forms. Use a hand maul stakes as it follows the patio outline. Screw forms to the stakes. Note: If you are or sledgehammer to drive the stakes. To the strip to the middle stake first, making installing straight 2 × 4 forms, drive prevent them from splitting, use a scrap sure the top is flush with the layout string. screws through the outsides of the 2 × 4 as a hammer block to absorb the Bend the form to follow the outline and stake and into the forms boards to blows. Drive a stake at each point where attach it to the other stakes. Check with a make them easier to remove later. a string intersects the patio outline. level as you install forms.
(continued)
Poured Concrete ■ 77
10 11Lay reinforcing wire mesh over the Place 4,000 psi concrete in the form, starting at the end farthest from the gravel base, keeping the edges 1 to 2” concrete source. Before pouring, construct access ramps so wheelbarrows can from the insides of the form. Overlap roll over the forms without damaging them, and coat the insides of the form with the mesh strips by 6” and tie them a release agent or vegetable oil to prevent the forms from sticking. Distribute the together with tie wire. Prop up the mesh concrete with a shovel or masonry hoe. As you fill, hammer against the outsides of on 2” wire bolsters placed every few the forms to eliminate air pockets. feet and tied to the mesh with wire. If required, install isolation board along the house foundation.
12 13Screed the surface with a long, straight 2 × 4: Have two Float the concrete surface with a bull float: Without people pull the board backward in a side-to-side sawing applying pressure, push and pull the float in straight, parallel motion, with the board resting on top of the form. As you work, passes, overlapping each pass slightly with the next. Slightly tip shovel in extra concrete to fill low spots or remove concrete up the leading edge of the float to prevent gouging the surface. from high spots and rescreed. The goal is to create a flat Stop floating once the surface is relatively smooth and has surface that’s level with the top of the form. a wet sheen. Be careful not to overfloat, indicated by water pooling on the surface. Allow the bleed water to disappear.
78 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
14 15
Use an edger to shape all edges of the slab that contact Cut a control joint (if required) using a 1” groover guided by the wood form. Carefully run the edger back and forth along a straight 2 × 4. In most cases, you’ll need to erect a temporary the form to create a smooth, rounded corner. Slightly lift the bridge to allow access for cutting in the center of the patio. leading edge of the tool as needed to prevent gouging. Take great care here. Be sure to cut grooves while concrete is still workable. Make several light passes back and forth until the groove reaches full depth, lifting the leading edge of the tool to prevent gouging.
16 17
Flatten ridges and create a smooth surface with a Cure the concrete by misting the slab with water, then magnesium trowel. This will create a smooth surface that covering it with a single piece of polyethylene sheeting. takes a finish well once the concrete has dried. Another Smooth out any air pockets (which can cause discoloration), finishing option is simply to skip additional floating and let and weight the sheeting along the edges. Mist the slab and the concrete set up until all the bleed water is gone. Then, reapply the plastic daily for 1 to 2 weeks. brush lightly with a push broom to create a nonslip “broomed” surface.
Poured Concrete ■ 79Poured Concrete Wall
B uilding vertically with poured concrete introduces a whole new dimension to this versatile material. And as much as walls may seem more challenging than For help with building a new footing, see pages 48 to 49. The footing should be at least 12 inches wide (2× wall thickness) and at least six inches thick slabs or casting projects, the basic building process is (1× wall thickness), and it must extend below the frost just as simple and straightforward. You construct forms line (or in accordance with the local building code). using ordinary materials, then fill them with concrete, If your wall will stand on a concrete patio or other and finish the surface. While tall concrete walls and slab, the sidebar on page 83 shows you how to install load-bearing structures require careful engineering and rebar in the slab for anchoring the wall. professional skills, a low partition wall for a patio or garden can be a great do-it-yourself project. The first rule of concrete wall building is knowing that the entire job relies on the strength of the form. A Tools & Materials ▸ cubic foot of concrete weighs about 140 pounds, which means that a three-foot-tall wall that is six inches thick Drill and 1⁄8” bit 16d and 8d nails weighs 210 pounds for each linear foot. If the wall is Hacksaw or Wood screws or 10 feet long, the form must contain over a ton of wet reciprocating saw deck screws concrete. And the taller the wall, the greater the pressure Pliers 8-gauge tie wire on the base of the form. If the form has a weak spot and Level Vegetable oil or the concrete breaks through (known in the trades as a Concrete mixing tools commercial blowout), there’s little chance of saving the project. So be Shovel release agent sure to brace, stake, and tie your form carefully. Concrete trowel Concrete mix This project shows you the basic steps for building Lumber (2 × 4, Plastic sheeting a three-foot-high partition wall. This type of wall can 2 × 2, and 1 × 2) Exterior-use typically be built on a poured concrete footing or a 3 ⁄4” exterior-grade anchoring cement reinforced slab that’s at least four inches thick. When plywood Heavy-duty masonry planning your project, consult your local building #3 steel reinforcing coating (optional) department for specific requirements, such as wall bar (rebar) Work gloves and eye size, footing specifications, and metal reinforcement in Hammer or mallet protection the wall. Note: This wall design is not suitable for Edger retaining walls, tall walls, or load-bearing walls.
In any setting, a poured concrete wall offers clean, sleek lines and a reassuringly solid presence. You can leave the wall exposed to display its natural coloring and texture. For a custom design element, you can add color to the concrete mix or decorate any of the wall’s surfaces with stucco, tile, or other masonry finishes.
80 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Wall Form Construction ▸
A wall form is built with two framed
sides (much like a standard 2 × 4
Pull wire
stud wall) covered with 3⁄4" plywood. 3
⁄4" plywood
The two sides are joined together
at each end by means of a stop
⁄4"
3
board, which also shapes the end plywood
of the finished wall. The form is
Spacer
braced and staked in position. Tie
wires prevent the sides of the form 2×4
frame
from spreading under the force of 2×2 frame
for stop
the concrete. Temporary spacers board
Stake
maintain proper spacing between
#3 rebar
the sides while the form is empty;
these are pulled out once the
concrete is placed. Concrete Stake Diagonal
3
⁄4" plywood footing bracing
stop board■ How to Create a Poured Concrete Wall 1 2
Build the frames for the form sides from 2 × 4 lumber and Cut one piece of 3⁄4” plywood for each side frame. Fasten the 16d nails. Include a stud at each end and every 16” in between. plywood to frames with 8d nails driven through the plywood Plan an extra 21⁄4” of wall length for each stop board. For walls and into the framing. Make sure the top edges of the panels longer than 8 ft., build additional frames. are straight and flush with the frames. (continued)
Poured Concrete ■ 81
3 4Drill holes for the tie wires: At each stud location, drill two Cut #3 rebar at 34”, one piece for each rebar anchor in the pairs of 1⁄8” holes evenly spaced and keep the holes close to footing. Cut rebar for three horizontal runs, 4” shorter than the stud faces. Drill matching holes on the other form side. the wall length. Tie the short pieces to the footing anchors using 8-gauge tie wire, and then tie the horizontal pieces to the verticals, spacing them 12” apart and keeping their ends 2” from the wall ends. To make a 90° turn, bend the bars on one leg of the wall so they overlap the others by 24”.
5 6
Spacer
Pull wire
Spacer Spacer
HandleCut 1 × 2 spacers at 6”, one piece for each set of tie wire Set the form sides in place. Install the stop boards with 2 × 2 holes. These temporary spacers will be used to maintain the frames for backing; fasten the frames to the form sides with screws. form width. Tie each pair of spacers to a pull wire, spacing Tie a loop of wire through each set of tie wire holes and position them to match the hole spacing. Then attach a piece of scrap a spacer near each loop. Use a stick to twist the loop strands wood to the end of the pull wire to serve as a handle. together, pulling the form sides inward, tight against the spacers.
82 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Building on a Concrete Slab ▸
A standard, reinforced 4”-thick concrete slab can Mark the locations for the rebar anchors along the be a suitable foundation for a low partition wall like the wall center: Position an anchor 4” from each end of the one shown in this project. The slab must be in good wall and every 24” in between. At each location, drill a condition, with no significant cracks or changes in level, 11⁄2”-diameter hole straight down into the concrete using and you should place the wall several inches away from a hammer drill and 11⁄2” masonry bit (above, left). Make the slab edge to ensure adequate support. To anchor the the holes 3” deep. Spray out the holes to remove all dust new wall to the slab and provide lateral stability, you’ll and debris using an air compressor with a trigger-type need to install rebar anchors in the slab, following the nozzle. Cut six pieces of #4 rebar at 16”. Mix exterior-use basic steps shown here. But before going ahead with the anchoring cement to a pourable consistency. Insert the project, be sure to have your plans approved by the local rods into the holes, and then fill the hole with the cement building department. (above, right). Hold the rods plumb until the cement sets (about 10 minutes). Let the cement cure for 24 hours.
Securing Braces on a Concrete Slab ▸ Fasten sheets of 3⁄4” plywood to the slab as an anchoring surface for form braces. Wall form Fasten the plywood with a few heavy-duty masonry screws driven into the slab. Butt the sheets against Diagonal the bottom of the form to bracing screwed provide the same support to plywood you would get from stakes. Screw diagonal form bracing directly to the plywood. You can also add a cleat behind 2× cleat the braces for extra support. 3 ⁄4” plywood anchored to slab Abut plywood to form base Concrete slab
(continued)
Poured Concrete ■ 83
7Make sure the form is centered over the footing. Check that the sides are plumb and the top is level. Secure the form with stakes and braces: Install a diagonal brace at each stud location, and stake along the bottom of the form sides every 12”. Fasten all stakes and braces to the form framing with screws. For long walls, join additional side pieces with screws for a tight joint with no gap along the plywood seam. Brace the studs directly behind the joint between sections. Coat the insides of the form with a release agent. If building on a slab (above, right), construct the form and then attach as a unit.
8 9Mix the first batches of concrete in a power mixer, being Place the concrete in the forms. Start at the ends and work careful not to add too much water—a soupy mix results in toward the center, filling the form about halfway up (no more weakened concrete. than 20” deep). Rap on the forms to settle out air bubbles and then fill to the top. Remove the spacers as you proceed.
84 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
10 11
Pull wireUse a shovel to stab into the concrete to work it around the Screed the top of the wall flat with a 2 × 4, removing spacers rebar and eliminate air pockets. Continue to rap the sides of as you work. After the bleed water disappears, float or trowel the forms with a hammer or mallet to help settle the concrete the top surface of the wall for the desired finish. Also round against the forms. over the edges of the wall with an edger, if desired.
12 13
Cut the loops of tie wire and remove the forms. Trim the
tie wires below the surface of the concrete and then patch
the depressions with quick-setting cement or fast-set repair
mortar. Trowel the patches flush with the wall surface.
Quick Tip ▸
To achieve a consistent wall color and texture, applyCover the wall with plastic and let it cure for two or three days. Remove the plastic. Sprinkle with water on hot or dry heavy-duty masonry coating with acrylic fortifier days to keep concrete from drying too quickly. using a masonry brush.
Poured Concrete ■ 85
Before86 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Poured Concrete Retaining Wall
P oured concrete has advantages and disadvantages as a building material for structural garden walls, such as this retaining wall. On the plus side: It can If the wall will be three feet or taller, you should have it engineered by a professional. Shorter retaining walls, sometimes called curb walls, often require less conform to just about any size and shape you desire stringent engineering, especially if they are located (within specific structural limitations); depending on in a garden setting or are to be used for planting beds your source, concrete can be a relatively inexpensive or terracing. The wall seen here is built in a fairly material; poured concrete is very longlasting; with cold climate, but the fact that the top is less than 36 professional engineering, you can build higher with inches above ground allows for a drainage base that poured concrete than with most other wall materials. is above the frost line, with the understanding that But if you live in a region where freeze/thaw cycles some shifting is likely to occur. The project was built exist, you’ll need to dig at least a foot past the frost in conjunction with poured concrete steps. Because line and provide plenty of good drainage to keep your the steps and walls are isolated with an isolation wall from developing vertical cracks. membrane, they are regarded as independent A properly engineered retaining wall is designed structures and neither is required to have footings using fairly complicated dimensional and force ratios. that extend below the frost line.
Four types of retaining wall
Counterfort Counterfort
Counterfort
Gravity wall Semigravity wall Cantilever wall
Counterfort wallPoured concrete retaining walls employ differing strategies to keep the earth at bay. Some, called gravity walls, rely almost exclusively on sheer mass to hold back the groundswell. These are very wide at the bottom and taper upward in both the front and the back. Unless you feel like pouring enough concrete to build a dam, don’t plan on a gravity wall that’s more than 3 ft. tall. A semigravity wall is somewhat sleeker than a gravity wall and employs internal reinforcement to help maintain its shape. A cantilevered wall has an integral bottom flange that extends back into the hillside where it is held down by the weight of the dirt that is backilled on top of it. This helps keep the wall in place. A counterfort wall is a cantilevered wall that has diagonal reinforcements between the back face of the wall and the flange.
Poured Concrete ■ 87
Tools & Materials ▸
1 1⁄ 2"
Shovel Concrete release
Circular saw agent 3
⁄ 4"
Power miter saw #3 rebar
Table saw Concrete 20" above grade
Drill/driver Sheet plastic
Level Concrete vibrator or
36"
Mason’s lines rubber mallet total
height
Compactable gravel Magnesium trowel
Tamper Edger
Bow rake Sprayer
Wheelbarrow Concrete stain
Float 2" AB plastic pipe
Edging tool Landscape fabric 16" below
grade
3
⁄4" plywood Drainage gravel
Tie wire Eye protection and
2 × 4 lumber work gloves
Deck screws Plastic sheeting
Retaining
wall
River
rock
Weephole 2"-dia.
black PE pipe
#3 rebar
Landscape
fabric
Class V88 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build a Concrete Retaining Wall 1 2
Excavate the construction area well beyond the edges Add a thick layer (at least 4 to 6”) of compactable gravel of the planned wall. Reserve some soil for backfilling and to the bottom of the excavation and tamp it thoroughly with transport some to lower areas in your yard that need building- a hand tamper or a rented plate compactor to create a solid up. For larger walls, you can save a lot of work by renting a foundation for the wall. Add additional base material in sandy small backhoe or other earthmoving equipment or hiring an or marshy soil. excavator. If your utilities company has flagged any pipes in the area, you must dig around them using hand tools only.
3 4 Stake
Braces
Straightedge cutting guideCut the form boards, usually from 3⁄4”-thick exterior-grade Level and stake the forms after doing as much pre- plywood with one sanded face. You may also use dimensional assembly as you can, including attaching the 1 × 4 front forms lumber. Do not use oriented-strand board or particleboard to create the lip. Run mason’s lines at the tops of the forms because they have insufficient strength. Do not use any sheet to use as a reference. Drive 2 × 4 stakes into the ground next goods that can weaken and delaminate from exposure to wet to the form braces and attach the braces to the stakes with concrete. Use a circular saw and cutting guide or a table saw deck screws. Wherever possible, stake the forms by driving to cut panels to width. screws through the outer member so they can be removed to facilitate stripping off the forms.
Poured Concrete ■ 89
5Stake the back forms as well as the front forms. You’ll have to get a little creative for this task in many cases, because much depends on the condition of the soil or ground surrounding the wall, as well as access to the forms both during and after the pour. Here, strips of plywood are secured to metal stakes driven into the hill behind the forms. The strips are then screwed to the braces on the back wall forms to hold them in position.
6 7Add rebar reinforcement to tie the integral footing and the Install weep holes. Choose drain pipe (black AB plastic is a wall together. Drive a length of rebar into the bottom of the wall good choice) around 2” in diameter and cut lengths that are area and then bend another piece and attach it to the rebar equal to the distance between the inside faces of the plywood stake with wire. Install these reinforcements every 2 to 3 ft. For form boards. Insert the pipes into the bottoms of the form so extra strength, connect them with a horizontal pieces of rebar. each end is flush against the inside face of the form. Install a weep hole drain every 6 ft. or so. Drive a long screw through the front panel and the back panel so the screw penetrates the form inside the weep drain, near the top. The ends of the screws will create supports for the drain pipe if the friction fails during the pour (as is likely).
90 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Add Decorative8 Elements to Forms ▸ One of the beauties of poured concrete is that it is pliable enough to conform to an endless number of decorative forming schemes. For the retaining wall seen here, a series of particleboard panels with beveled edges are attached at regular intervals to the inside faces of the outer form to create a very familiar recessed panel appearance. The panels (beveled edges are cut on a table saw) should be attached with construction adhesive and short screws so there are not gaps that concrete can seep into. Be sure to use a release agent.
Vegetable oilApply a release agent to the inside surfaces of the forms. You can purchase commercial release agent product or simply brush on a light coat of vegetable oil or mineral oil. Do not use soap (it can weaken the concrete surface) or motor oil (it is a pollutant).
(continued)
Poured Concrete ■ 91
9 Colored Concrete ▸
The concrete mix seen here was pretinted at the
concrete mixing plant. If you do not want a gray
concrete structure, using tinted concrete adds color
without the need to refresh paint or stain. However, the
process is not cheap (about $60 per yard additional),
the final color is unpredictable, and you’ll have to
tint the concrete to match if you need to repair the
structure in the future. The pigment that is added can
also have unforeseen effects on the concrete mixture,
such as accelerating the set-up time.Place the concrete. Most walls call for a 4,000psi mixture (sometimes called 5-bag). You can mix concrete by hand, rent an on-site power mixer, haul your own premixed concrete in a rental trailer, or have the concrete delivered. Begin filling the form at one end of the wall and methodically work your way toward the other end. Have plenty of help so you can start tooling the concrete as soon as possible.
10 11
Concrete
vibratorHold a panel of sheet stock behind the forms to direct the Settle the concrete in the forms as you work. For best concrete into the form and prevent it from spilling out. results, rent a concrete vibrator and vibrate thoroughly before screeding. Do not get carried away—overvibrating the concrete can cause the ingredients to separate. A less effective alternative for vibrating (requiring no rental tools) is to work the concrete in with a shovel and settle it by rapping the forms with a rubber mallet.
92 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
12 13
Strike off, or “screed,” the concrete so it is level with the Tool the concrete once the bleed water evaporates, tops of the forms. Use a piece of angle iron on square tubing, if desired. For a smoother top, float the surface with a or a 2 × 4, as a screed. Move the screed slowly across the magnesium trowel or darby. Run the edger along the top edges forms in a sawing motion. Do not get ahead of the concrete. The on at least the front edge and preferably the back as well. material behind the screed should be smooth and level with no dips or voids.
14 15
Cover the concrete surface with plastic sheeting to cure, To backfill, first shovel in an 8 to 12” deep layer of drainage especially during hot weather. If it is very hot and dry, lift the plastic gravel (1 to 2” dia.), and then place a layer of landscape fabric off and douse the concrete with fresh water twice a day to slow over the gravel to keep dirt out. Shovel dirt over the gravel and down the drying. Drying too fast can cause cracking and other tamp it lightly until the desired grade is achieved. concrete failures. Wait at least two days before removing the forms.
Poured Concrete ■ 93Cast Concrete
C asting decorative objects for the home and yard is an entertaining and creative exercise in handling concrete. Locating and making forms Making your owns forms is another fun exercise in creativity. Melamine-coated particleboard is a great material for this job because it holds its shape and the is a challenge itself, and the specific nature of the concrete will not stick to the surface. When combined objects you eventually cast is often dictated by with other materials such as the metal flashing used the potential you see in everyday objects that to form the patio tabletop in this chapter, your casting you encounter. options are practically unlimited. The best forms for casting are rigid or semirigid For more complex and sophisticated castings, you with a slick surface and the ability to contain water. can buy reusable forms in a very wide array of shapes Plastic and rubber objects are ideal, but you can really and sizes. Garden benches, birdbaths, landscape use just about any material, especially if you use it for edging, pavers, and statuary are just some of the a single casting and are not concerned about breaking objects you can cast with a couple bags of concrete it when you release the cast object. Some examples and a purchased form. The best source for concrete of useful “found” forms include five-gallon plastic casting forms is the Internet (see Resources section). buckets (insert a smaller bucket or a tube to cast a One of the best reasons to cast your own large concrete pot); trash can lids (pavers); nesting decorative and functional objects from concrete is that plastic bowls (pots and planters); or any sphere you can customize the finished look by coloring the shapes, such as a basketball, that can be split in two concrete or using creative surface treatments such as (decorative orbs, bowls). the footsteps in the pavers seen above.
Casting concrete is a DIY-friendly way to gain experience with handling concrete. No matter your masonry skills, there is a casting project that will challenge and reward you. Projects can be made using purchased molds or everyday objects.
94 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Introduction to Casting Many objects can be used as forms for casting concrete. is a good choice because the melamine side does not Semirigid items work best because they require no require a release agent. Wood should be treated with a special preparation, often include embossed shapes or release agent like nonstick cooking spray. designs, and are usually easy to strip from the cast object. You’ll need to reinforce large concrete objects Once you try casting, you’ll begin to think of every with metal rods and mesh. Be sure to keep metal away inanimate object as a potential “form” for a concrete from the edges. Mix in synthetic reinforcing fibers if structure. Start with simple, easy-to-cast forms such not included in your mix. You can purchased bagged as plastic bowls or buckets. Choose forms that have concrete with fiber reinforcement blended in at the interesting textures. Consider how you will use the plant. These products are ideal for large castings cast concrete when the project is complete: Will it be that will undergo stress, such as stepping stones or functional or decorative? You may decide to create a tabletops. For small items, use sand mix. In both form to suit your needs cases, add acrylic fortifier to make the mixture more Constructed forms can cast items of practically slippery without decreasing strength. Add a coloring any size or shape. For flat items, such as tabletops agent (liquid or dry) to the mixture to enhance the and stepping stones, melamine-coated particleboard finished piece.
■ Sample Casting Projects
A deck bowl is cast using two nesting mixing bowls. This Sand casting is a great way to use up the leftovers from a technique can be used with plastic bowls and buckets and larger poured concrete project. To make this birdbath, you planters of all sizes. Larger containers should be split in half simply pile up some coarse wet sand and pour the leftover and taped back together so you can extract the cast object concrete onto the pile. Birds love the rough texture of the more easily. We used sand mix with acrylic fortifier and black concrete surface. concrete pigment for this deck bowl.
Poured Concrete ■ 95■ Garden Column Prefabricated concrete casting forms give you the ability to make objects for your yard and garden that rival the best (and very expensive) artwork pieces sold at garden centers. Garden benches and birdbaths are among the most popular, but you can locate an array of forms for just about any objects you can imagine. Because most of the objects cast with readymade forms feature grooves, flutes, or complex patterns, you’ll have the best luck if you use a relatively wet mixture of concrete with small or sand-only aggregate. Adding latex bonding agent or acrylic fortifier also makes the concrete more slippery so it can conform to odd shapes more readily, but these agents do not reduce concrete strength, as adding more water does. If your cast project will be placed outdoors, apply a penetrating concrete sealer about a week after the casting.
Tools & Materials ▸
Shovel Nonstick cooking
Mortar box spray
Concrete forms Duct tape
Bagged concrete mix Exterior landscape
(fiber reinforced) adhesive
Acrylic fortifierPrefabricated casting forms typically are made from rugged This classical concrete column is cast using a simple PVC so they may be reused many times. You can mix and plastic form purchased from an Internet supplier (see match the forms to create different objects. The forms above Resources). It can be used to support many garden items, include a column form with grapevine or fluted insert, two including a display pedestal, a birdbath, or a sundial. different pedestal shapes, and an optional birdbath top.
96 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Cast a Garden Column 1 2
Choose a column form insert Choose a sturdy, level work surface. Set the column form upright on a small (optional) and slide it into the column piece of scrap plywood. Tape down the form with duct tape, keeping the tape clear form as a liner so the edges meet neatly. of the form top. Mix a batch of fiber-reinforced concrete with an acrylic fortifier and Tape the column together at the seam. shovel it into the forms. Rap the forms with a stick to settle the concrete and strike Coat the insides of all form parts with a off the excess with a screed. Run additional tape “hold-downs” over the top of the very light mist of nonstick cooking spray column form to secure it to the plywood scrap tightly enough that the concrete will as a release agent. not run out from the bottom.
3 4
Set another scrap of plywood onto the top of the column Apply exterior landscape adhesive to the top of the base form and weight it down. Let the parts dry for two days and pedestal and set the column end into the adhesive so the then release them from the forms. Wash and rinse the parts to column is centered. Bond the top pedestal in the same manner. remove dusty residue. Apply penetrating sealant. If it is not nearby, transport the column and pedestals to the location before bonding the parts.
Poured Concrete ■ 97■ Patio Tabletop Casting concrete is a good way to produce some types of replacement parts, such as a new top for this old iron patio table base. To make the form for this project, a strip of galvanized roll flashing is inserted inside a ring of finish nails to create a circular shape. Larger tabletops should have rebar or rewire reinforcement, but this 24-inch-diameter top is small enough that fiber reinforcement strands are sufficient.
Tools & Materials ▸
Aviator snips Concrete colorant
Hammer Galvanized metal
Caulk gun roll flashing
Magnesium float 6d nails
Pencil Caulk
Drill/driver Duct tape
Rubber mallet Melamine-coated
Hammer particleboard This round patio tabletop was cast with fiber-reinforced
Reinforced concrete Tabletop hardware concrete tinted yellow. It is a much simpler version of the
mix String kitchen island countertop cast on pages 100 to 107. By casting
Acrylic fortifier Work gloves your own top, you can custom fit any table base you may have.■ How to Cast a Round Tabletop 1 2 1 1⁄ 2” metal flashing strip
12" radius Duct
tapeCut a piece of 3⁄4” melamine (or just about any other sheet Drive 6d finish nails on the circle line at 6” intervals. Keep stock) to 30 × 30” and drive a small nail in the exact center. Tie the nails perpendicular. Cut a 11⁄2” wide by 80”-long strip of string to the nail and tie a pencil to the other end, exactly 12” galvanized (not aluminum) flashing using aviator snips. Fit the away form the nail. Pull the string tight and use this “compass” flashing inside the circle with the cut edge down (factory edge to draw a 12” radius (24” diameter) circle. up). Let the flashing spring out inside the circle and adjust so the circle is even. Tape the ends of the flashing with duct tape on the outside of the form.
98 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Caulk liberally around the outside3 edge of the flashing where it meets the base. After the caulk dries, fill the form with a relatively stiff mix of fiber- reinforced concrete. Add acrylic fortifier and pigment (if desired) to the water before mixing the concrete. Pound the form base gently with a rubber mallet to settle the concrete. Also, work a stick around the edges of the concrete form to help settle the concrete and make sure there are no voids.
Strike off the the top of the concrete4 with a wood screed and fill any voids or dips in the surface with fresh concrete. Let the concrete set up until the bleed water that rises to the surface evaporates. Then, float the surface with a wood or magnesium float to create a smooth, hard surface. Do not overwork the float, however, as this will draw aggregate to the surface and weaken the pour.
Let the concrete cure for at least5 two days, then remove the flashing, and release the tabletops. Grind and polish if you wish (see page 107). Then, attach the top to the table base. The table base shown here has screwholes in the bearing ring, so we marked the screw locations on the underside of the tabletop and then drilled holes for screw anchors. Seal the surface.
Poured Concrete ■ 99
Kitchen Countertop
C ast concrete countertops have many unique
characteristics. They are durable, heat resistant,
and relatively inexpensive (if you make them yourself).
homeowners. In addition to keeping the mess and dust
out of your living spaces, working in a garage or even
outdoors lets you cast the countertops with the finished
But most of all, they are highly attractive and a great surface face down in the form. This way, if you do a
fit in contemporary kitchens or bathrooms. careful job building the form, you can keep the grinding
A concrete countertop may be cast in place and polishing to a bare minimum. In some cases, you
or formed offsite and installed like a natural stone may even be able to simply remove the countertop from
countertop. Casting offsite makes more sense for most the form, flip it over, and install it essentially as is.
Tools & Materials ▸
Tape measure Pliers Black or colored Bagged concrete
Pencil Concrete mixer silicone caulk countertop mix or
Table saw or 5-gal. buckets Grinding and polishing high/early mix rated
circular saw Shovel pads for 5,000 psi
Jigsaw Wheelbarrow Melamine-coated Paste wax
Drill and right-angle Wooden float particleboard for Work gloves and eye
drill guide Variable speed angle constructing the form protection
Level grinder with Concrete sealer
Carpenter’s square grinding pads Coloring agent (liquid If installing sink:
Reciprocating saw with Belt sander or powder) Knockout for faucet
metal-cutting blade Automotive buffer Compass Buffing bonnet for
Aviation snips Insulation board #3 rebar polisher
2" coarse wallboard Plastic sheeting Tie wire Faucet set
screws Rubber mallet Panel or silicone Sink
Deck screws (3, 31⁄2) Welded wire mesh for adhesive Polyurethane varnish
Wire mesh reinforcement
Building a custom concrete countertop like this is an easier project than you might think. All of the building materials and
techniques are covered in this book.100 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Planning a Concrete Countertop ▸
G
A
B E H
F
C
I
L
J
K
DThe basic supplies needed to build your countertop form and cast the countertop include: (A) welded wire mesh for reinforcement; (B) black or colored silicone caulk; (C) grinding and polishing pads; (D) melamine-coated particleboard for constructing the form; (E) concrete sealer; (F) coloring agent (liquid or powder); (G) bagged concrete countertop mix or high/early mix rated for 5,000 psi; (H) paste wax; (I) knockout for faucet, if installing sink; (J) buffing bonnet for polisher; (K) faucet set; and (L) sink.
Custom Features: Concrete countertops are normally 48” long × 24” deep × 31⁄2” thick will require 21⁄3 cu. ft. of cast as flat slabs, but if you are willing to put a little mixed concrete (48 × 24 × 3.5 / 1,728 = 21⁄3) or four 80-lb. more time and effort into it, there are many additional bags of countertop mix. features you can create during the pour. A typical 3”-tall backsplash is challenging, but if you have room behind the faucet you can create a 3⁄4”-tall backsplash shelf in the backsplash area. Or, if you search around for some additional information, you can learn how to cast a drainboard directly into the countertop surface. And there is practically no end to the decorative touches you can apply using pigments and inserts.
Estimating Concrete for Countertops: After you design your project and determine the actual dimensions, you’ll need to estimate the amount of concrete you’ll need. Concrete is measured by volume Countertop mix is specially formulated concrete in cubic feet; multiply the length by the width and then countertop mix designed for use in either precast or by the thickness of the finished countertop for volume cast-in-place projects. Countertop mix contains in cubic inches, then divide the sum by 1,728 for additives that improve the workability, strength, and cubic feet. For example, a countertop that will be finish of the mix.
Poured Concrete ■ 101
■ How to Cast a Concrete Countertop
1 2
Make the form parts. First, cut 11⁄2"-wide strips of 3⁄4" Use a power drill mounted in a right-angle drill guide (or
melamine-coated particleboard for the form sides. Cut the use a drill press) to drill 1⁄4"-dia. guide holes for 3" deck screws
strips to length (26 and 811⁄2" as shown here) and drill two at 6" intervals all the way through the tops of the form sides.
countersunk pilot holes 3⁄8" in from the ends of the front and Countersink the holes so the screw heads will be recessed
back form sides. Assemble the strips into a frame by driving slightly below the surface.
a 2" coarse wallboard screw at each pilot hole and into the
mating ends of the end form strips.
3 4
Attach the form sides to the base. Center the melamine- Make the sink knockout blanks by stacking two pieces of
strip frame pieces on the base, which should have the 3
⁄4" melamine. The undermount sink we used requires a 20 ×
melamine coating face-up. Test the corners with a carpenter’s 31” knockout with corners that are rounded at a 2" radius. Cut
square to make sure they’re square. Drive one 31⁄2" deck screw two pieces of 3⁄4"-thick MDF to 20 × 31" square using a table
per form side near the middle. The screwheads should be saw if you have one. With a compass, mark 2"-radius curves at
slightly below the top edges of the forms. Check for square each corner for trimming. Make the trim cuts with a jigsaw (as
again, and continue driving the 31⁄2" screws at 6" intervals shown in photo). Cut just outside the trim line and sand up to it
through the pilot holes. Check for square frequently. Note: Do with a pad sander for a smooth curve.
not drive any screws up through the underside of the form
base—you won’t be able to lift the countertop and access the
screws when it’s time to strip off the forms.102 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
5 6
Shape the knockout. Clamp the two pieces of melamine Install the sink knockout. Because gluing the faces face-to-face for the knockout and gang-sand the edges and together can add height to the knockout (and cause the corners so they’re smooth and even. A belt sander on a concrete finishing tools to bang into it when they ride on the stationary sanding station or an oscillating spindle sander form tops), attach each blank directly to the layer below it works great for this. Don’t oversand—this will cause the sink using countersunk screws. Keep the edges aligned perfectly, knockout to be too small. especially if you’re planning to install an undermount sink.
7Faucet Knockouts Option: If your sink faucet will not be mounted on the sink deck, you’ll need to add a knockout to your form for the faucet hole (try and choose a single- handle faucet), according to the requirements of the faucet manufacturer. You can order knockouts from a concrete countertop supplies distributor, or you can create them with PVC pipe that has an outside diameter equal to the required Make the form watertight. Seal exposed edges of the sink faucet hole size. To anchor the PVC knockout, cover one end knockout with fast-drying polyurethane varnish, and then with a flat cap made for that size tubing. Drill a guide hole caulk the form once the varnish is dry. Run a very thin bead of through the center of the cap so you can secure it with a colored silicone caulk (the coloring allows you to see where screw. The top of the cap should be exactly flush with the the caulk has been laid on the white melamine) in all the form sides once it is installed. Before securing, position the seams and then smooth carefully with a fingertip. In addition to knockout next to a form side and compare the heights. If keeping the wet concrete from seeping into gaps in the form, the knockout is taller, file or sand the uncapped end so their the caulk will create a slight roundover on the edges of the lengths match. concrete. Caulk around the bottoms of the knockouts as well.
(continued)
Poured Concrete ■ 103
8
Variation: If your countertop is more than 2" thick, use #3 Add reinforcement. Cut a piece of welded wire (also called
rebar (3⁄8" dia.) for the primary reinforcement. Do not use rebar rewire) with a 4 × 4" grid so it’s 2" smaller than the interior
on thinner countertops, as the rebar will necessarily be too form dimensions. Make a cutout for the sink and faucet
close to the surface and can telegraph through. Bend the rebar knockouts, making sure the rewire does not come closer than
to fit around the perimeter of the form using a rebar or conduit 1" to any edge, surface, or knockout. Flatten the rewire as best
bender. The rebar needs to be at least 1" away from all edges you can and then hang it with wires that are attached to the
(including knockouts) and 1" away from the top surface. Tie the tops of the forms with screws (you’ll remove the screws and
ends of the rebar with wire and set it in the form on temporary cut the wires after the concrete is placed).
1" spacers.
9 10
Clamp or screw the base of the form to a sturdy workbench Blend water with liquid cement color (if desired) in a
or table so the form cannot move during the critical finishing 5-gal. bucket prior to adding to the mixer.
and curing stages. Check for level and insert shims between
the worktop and the benchtop if needed for leveling. If you’re
concerned about mess, slip a sheet of 3-mil plastic on the floor
under the workbench.104 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
11 12
Slowly pour concrete countertop mix Fill the countertop form, making sure to pack the concrete into corners and press into the mixer and blend for a minimum it through the reinforcement. Overfill the form slightly. of 5 minutes. Properly mixed material will flow easily into molds. Add small amounts of water as necessary to achieve the desired consistency.
13 14
Vibrate the form vigorously as you work to settle concrete into all the voids. You Strike off excess concrete from can rent a concrete vibrator for this purpose, or simply strike the form repeatedly the form using a 2 x 4 drawn along the with a rubber mallet. If you have a helper and a sturdy floor and worktable, lift up and tops of the forms in a sawing motion. If down on the ends of the table, bouncing it on the floor to cause vibrations (this is a voids are created, pack them with fresh very effective method if you can manage it safely). Make sure the table remains level concrete and restrike. Do not overwork when you’re through. the concrete.
(continued)
Poured Concrete ■ 105
15 16
Snip the wire ties holding the rewire mesh once you are Smooth the surface of the concrete with a metal screeding
certain you won’t need to vibrate the form any further. Embed tool, such as a length of angle iron or square metal tubing.
the cut ends attached to the rewire below the concrete surface. Work slowly with a sawing motion, allowing the bleed water
to fill in behind the screed. Since this surface will be the
underside of the countertop, no further tooling is required.
Cover the concrete with plastic and allow the concrete to dry
undisturbed for three to five days.
17 18
Remove the plastic covering and then unscrew and remove Flip the countertop so the finished surface is exposed
the forms. Do not pry against the fresh concrete. In most (you’ll need a helper or two). Be extremely careful. The best
cases, you’ll need to cut apart the sink knockout to prevent technique is to roll the countertop onto an edge, position
damaging the countertop when removing it. Drill a starter hole several shock-absorbing sleepers beneath it (rigid insulation
and then carefully cut up to the edge of the knockout. Cut the board works very well), and then gently lower the countertop
knockout into chunks until you can remove it all. The edges of onto the sleepers.
the concrete will be fragile, so be very careful.106 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
19 20
To expose the aggregate and create a very polished finish, grind the countertop Clean and seal the concrete with surface. Use a series of increasingly fine grinding pads mounted on a shock-protected several coats of quality concrete sealer 5” angle grinder (variable speed). This is messy work and can go on for hours to get (one with penetrating and film-forming the desired result. Rinse the surface regularly with clean water and make sure it stays agents). For extra protection and a wet during grinding. For a gleaming surface, mount still finer pads (up to 1,500 grit) on renewable finish, apply a coat of paste the grinder and wet-polish. wax after the last coat of sealer dries.
21 22
Mount the sink (if undermount). Sinks are easier to install Install the countertop and hook up the plumbing. Make sure prior to attaching the countertop on the cabinet. Attach the the island cabinet is adequately reinforced and that as much sink according to the manufacturer’s directions. Undermount plumbing as possible has been taken care of, and then apply a sinks like this are installed with undermount clips and thick bead of panel adhesive or silicone adhesive to the tops silicone adhesive. Self-rimming sinks likely will require some of the cabinets and stretchers. With at least one helper, lower modifications to the mounting hardware (or at least you’ll need the countertop onto the base and position it where you wish. to buy some extra-long screws) to accommodate the thickness Let the adhesive dry overnight before completing the sink and of the countertop. faucet hookups.
Poured Concrete ■ 107Brick & Block B rick and block add an earthen, structural feel to an indoor or outdoor environment. The material spans many applications and the array of block material available today in different textures, colors, and sizes allows you to customize the projects in this chapter to your liking. If you are just learning masonry and stonework skills, a brick and block project is a great place to start. Most brick and block projects are permanently bound together with mortar, including setting the first course into a bed of mortar on a stable footing. In some cases, however, the masonry units can be dry-laid (stacked without using mortar) and then bound together with a coat of stucco or masonry veneer that is applied to the surfaces after the stacking is completed. With the exception of a dry-stacked stone wall, this kid of wall represents the easiest starter masonry project. Be certain the base is stable, however, as any movement will cause visible cracking and eventual failure if repairs are not enacted quickly.
In this chapter: • Brick & Block Basics • Dry Block Wall • Block Retaining Wall • Outdoor Kitchen • Brick Barbecue • Brick Planter • Brick Pillars • Brick Archway • Brick Wall Veneer • Mortared Brick Patio
■ 109
Brick & Block Basics
L aying brick and block is a precise business. Many
of the tools necessary for these projects relate
to establishing and maintaining true, square and
A B C
level structures, while others relate to cutting the
masonry units and placing the mortar. It makes sense
to purchase tools you’ll use again, but it’s more cost
effective to rent specialty items, such as a brick splitter.
Mortar mixes: (A) Type N, a medium-strength mortar for
above-grade outdoor use in nonload-bearing (freestanding) walls,
barbeques, chimneys, and tuck-pointing; (B) refractory mortar, a
calcium aluminate mortar that is resistant to high temperatures,
used for mortaring around firebrick in fireplaces and barbeques;
(C) Type S, a high-strength mortar for outdoor use at or below D
grade, typically used in foundations, retaining walls, driveways,
walks, and patios; (D) mortar tint for coloring mortar; (E) and you’ll E
need water for mixing mortar so a hose is needed (a sprayer
attachment is needed later to clean surface).
D
E
A
B
C
F
J
H
I G
Common types of brick and block used for residential construction include: decorative block (A) available colored or plain;
decorative concrete pavers (B); fire brick (C); standard 8 × 8 × 16" concrete block (D); half block (E); combination corner block (F);
queen-sized brick (G); standard brick pavers (H); standard building bricks (I); and limestone wall cap (J).110 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
A
D
E
B C
F G
L
J
K
H
I
P
O
M
N
M
T W
Q
U
S
R
V
Y
X
ZMason’s tools include: a story pole (A) for checking stacked masonry units; masonry hoe (B) and mortar box (C) for mixing mortar; a bucket (D) and stiff bristle brushes (F) for removing stains and loose materials; circular saw and masonry-cutting blades (E) for scoring brick and block; level (G) for checking stacked masonry units; brick tongs (H) for carrying multiple bricks; mason’s trowel (I) for applying mortar; rubber mallet (J) for setting paver stones; mortar bag (K) for filling horizontal joints; mortar hawk (L) for holding mortar; masonry chisels (M) for splitting brick, block, and stone; pointing trowel (N) for placing mortar on brick and block walls; sled jointer (O) for finishing long joints; mason’s hammer (P) for chipping brick and stone; a tape measure and chalk line (Q) for marking layout lines on footings or slabs; mason’s string (R) and line blocks (T) for stacking brick and block; a line level (S) for making layouts and setting slope; jointers (U) for finishing mortar joints; aviation snips (V) for trimming metal ties and lath; pipe clamps (W) for aligning brick and block to be scored; a framing square (X) for setting project outlines; 3⁄8” dowels (Y) for spacers between dry-laid masonry units; caulk gun (Z) for sealing around fasteners and house trim.
Brick & Block ■ 111
■ Planning & Techniques
L ike other masonry projects, brick and block projects
must start with careful planning. You need to
identify the construction techniques and methods
that are appropriate for the project, practice any Single-wythe
block wall
techniques you need to learn, and estimate and order
your materials.
Double-wythe
brick wall
Estimating Bricks & Blocks ▸
Single-wythe
Standard brick brick wall
pavers for walks surface area (sq. ft.) × 5 =
and patios (4 × 8) number of pavers needed
Standard bricks surface area (sq. ft.) × 7 =
for walls and number of pavers needed
pillars (4 × 8) (single brick thickness)
Interlocking area of wall face (sq. ft.) × 1.5 = Select a construction design that makes sense for your
project. There are two basic methods used in stacking brick or
block number of blocks needed
block. Structures that are only one unit wide are called single
8 × 8 × 16 wythe and are typically used for projects like brick barbecues
concrete for Height of wall (ft.) × length of wall or planters, and for brick veneers. Double-wythe walls are two
freestanding walls × 1.125 = number of blocks needed units wide and are used in free-standing applications. Most
concrete-block structures are single wythe.
3'
Keep structures as low as you can. Local codes require Add a lattice panel or another decorative element to
frost footings and additional reinforcement for permanent permanent walls to create greater privacy without having to
walls or structures that exceed maximum height restrictions. add structural reinforcement to the masonry structure.
You can often simplify your project by designing walls that are
below the maximum height.112 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Plan a Brick or Block Project Wall
2× wall width
Wall
widthFrost line Wall width × 2
12"
8"
Shown
cutawayFrost footings are required if a structure will be more than Pour a reinforced concrete slab for brick and block 2 ft. tall or if it is tied to another permanent structure. Frost structures that are freestanding and under 2 ft. tall. The slab footings should be twice as wide as the structure they support should be twice as wide as the wall, flush with ground level, and should extend 8 to 12” below the frost line (pages 46 to 47). and at least 8” thick. Check with building codes for special requirements. Slabs are poured using the techniques for pouring a sidewalk (pages 50 to 55).
9" nominal
8 5⁄ 8" actualDo not add mortar joint thickness to total project dimensions Test project layouts using 3⁄8” spacers between masonry when planning brick and block projects. The actual sizes of units to make sure the planned dimensions work. If possible, bricks and blocks are 3⁄8” smaller than the nominal size to allow create a plan that uses whole bricks or blocks, reducing the for 3⁄8”-wide mortar joints. For example, a 9” (nominal) brick has amount of cutting required. an actual dimension of 85⁄8”, so a wall that is built with four 9” bricks and 3⁄8” mortar joints will have a finished length of 36” (4 × 9”).
Brick & Block ■ 113
■ Reinforcing Brick & Block Structures
3
⁄4" plastic tubing
Metal tie
Metal rebar
For double-wythe brick projects, use metal ties between For block projects, fill the empty spaces (cores) of the block
wythes for reinforcement. Insert ties directly into the mortar with thin mortar. Insert sections of metal rebar into the mortar
2 to 3 ft. apart, every third course. Insert metal rebar into the to increase vertical strength. Check with your local building
gap between wythes every 4 to 6 ft. (check local building inspector to determine reinforcement requirements, if any.
codes). Insert 3⁄4"-diameter plastic tubing between wythes to
keep them aligned. Pour a thin mixture of mortar between the
wythes to improve the strength of the wall.
Provide horizontal reinforcement on brick or block walls by setting metal reinforcing strips into the mortar every third course.
Metal reinforcing strips, along with most other reinforcing products, can be purchased from brick and block suppliers. Overlap the
ends of metal strips 6" where they meet.114 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Tips for Working with Brick ▸
Make practice runs on a 2 × 4 to help you perfect Test the water absorption rate of bricks to determine your mortar-throwing (pages 118 to 119) and bricklaying their density. Squeeze out 20 drops of water in the same techniques. You can clean and reuse the bricks to make spot on the surface of a brick. If the surface is completely many practice runs if you find it helpful, but do not dry after 60 seconds, dampen the bricks with water reuse the bricks in your actual project—old mortar can before you lay them to prevent them from absorbing impede bonding. moisture from the mortar before it has a chance to set.
Use a T-square and pencil to mark several bricks for Mark angled cuts by dry-laying the project (as shown cutting. Make sure the ends of the bricks are all aligned. with pavers above) and setting the brick or block in position. Allow for 3⁄8” joints in mortared projects. Pavers have spacing lugs that set the spacing at 1⁄8”. Mark cutting lines with a pencil using a straightedge where practical to mark straight lines.
Brick & Block ■ 115
■ How to Score & Cut Brick
Score all four sides of the brick first with a brickset chisel Option: When you need to split a lot of bricks uniformly and
and maul when cuts fall over the web area and not over the quickly, use a circular saw fitted with a masonry blade to score
core. Tap the chisel to leave scored cutting marks 1⁄8 to 1⁄4" the bricks, then split them individually with a chisel. For quick
deep, and then strike a firm final blow to the chisel to split the scoring, clamp them securely at each end with a pipe or bar
brick. Properly scored bricks split cleanly with one firm blow. clamp, making sure the ends are aligned. Remember: Wear eye
protection when using striking or cutting tools.
■ How to Angle-cut Brick
1 2
Pivot
point
Cutting
marks
Mark the final cutting line on the brick. To avoid ruining Keep the chisel stationary at the point of the first cut, pivot
the brick, you will need to make gradual cuts until you reach it slightly, and then score and cut again. It is important to keep
this line. Score a straight line for the first cut in the waste area the pivot point of the chisel at the edge of the brick. Repeat
of the brick about 1⁄8" from the starting point of the final cutting until all of the waste area is removed.
line, perpendicular to the edge of the brick. Make the first cut.116 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Use a Brick Splitter 1 2
A brick splitter makes accurate, consistent cuts in bricks and Once the brick is in position on the splitter table, pull down pavers with no scoring required. It is a good idea to rent one if sharply on the handle. The cutting blade on the splitter will your project requires many cuts. To use the brick splitter, first cleave the brick along the cutting line. Tip: For efficiency, mark mark a cutting line on the brick, and then set the brick on the cutting lines on several bricks at the same time. table of the splitter, aligning the cutting line with the cutting blade on the tool.
■ How to Cut Concrete Block 1 2
Mark cutting lines on both faces of Use a mason’s chisel and maul to split Option: Cut half blocks from combination the block, and then score 1⁄8 to 1⁄4”-deep one face of the block along the cutting corner blocks. Corner blocks have preformed cuts along the lines using a circular saw line. Turn the block over and split the cores in the center of the web. Score equipped with a masonry blade. other face. lightly above the core, and then rap with a mason’s chisel to break off half blocks.
Brick & Block ■ 117
■ Mixing & Placing Mortar
A professional bricklayer at work is an impressive
sight, even for do-it-yourselfers who have completed
numerous masonry projects successfully. The mortar
enough for you to deliver a controlled, even line that
holds its shape after settling. Note how much water
you use in each batch, and record the best mixture.
practically flies off the trowel and seems to end up in Mix mortar for a large project in batches; on
perfect position to accept the next brick or block. a hot, dry day a large batch will harden before you
Although “throwing mortar” is an acquired skill know it. If mortar begins to thicken, add water (called
that takes years to perfect, you can use the basic retempering); use retempered mortar within two hours.
techniques successfully with just a little practice.
The first critical element to handling mortar
effectively is the mixture. If it’s too thick, it will fall
off the trowel in a heap, not in the smooth line that Tools & Materials ▸
is your goal. Add too much water and the mortar
becomes messy and weak. Follow the manufacturer’s Mortar mix Mason’s trowel
directions, but keep in mind that the amount of water Mortar box Bricks
specified is an approximation. If you’ve never mixed Masonry hoe Mortar tint
mortar before, experiment with small amounts until Plywood Work gloves
you find a mixture that clings to the trowel just long
■ How to Mix & Place Mortar
1 2
Empty mortar mix into a mortar box and form a depression Set a piece of plywood on blocks at a convenient height,
in the center. Add about 3⁄4 of the recommended amount of and place a shovelful of mortar onto the surface. Slice off a
water into the depression, and then mix it in with a masonry strip of mortar from the pile using the edge of your mason’s
hoe. Do not overwork the mortar. Continue adding small trowel. Slip the trowel point-first under the section of mortar
amounts of water and mixing until the mortar reaches the and lift up.
proper consistency. Do not mix too much mortar at one
time—mortar is much easier to work with when it is fresh.118 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
3 4
Snap the trowel gently downward to dislodge excess “Furrow” the mortar line by dragging the point of the trowel mortar clinging to the edges. Position the trowel at the starting through the center of the mortar line in a slight back-and-forth point, and “throw” a line of mortar onto the building surface. motion. Furrowing helps distribute the mortar evenly. A good amount is enough to set three bricks. Do not get ahead of yourself. If you throw too much mortar, it will set before you are ready.
Mortar Mixing Tips ▸
Adding tint to mortar works best if you add the same Use a stiff (dry) mix of mortar for tuck-pointing—it’s
amount to each batch throughout the project. Once you less likely to shrink and crack. Start by mixing Type N
settle on a recipe, record it so you can mix the same mortar mix with half the recommended water. Let the
proportions each time. mixture stand for one hour, and then add the remaining
water and finish mixing.
Brick & Block ■ 119
■ Layering Brick
P atience, care, and good technique are the key
elements to building brick structures that have
a professional look. Start with a sturdy, level footing
(pages 46 to 49), and don’t worry if your initial
bricklaying attempts aren’t perfect. Survey your work
often and stop when you spot a problem. As long as the
mortar’s still soft, you can remove bricks and try again.
This section features one method of brick wall
construction: laying up the ends of the wall first,
and then filling in the interior bricks. The alternate
method, laying one course at a time, is shown with
concrete block (pages 124 to 127).
Tools & Materials ▸
Gloves Jointing tool
Trowel Mortar
Chalk line Brick
Level Wall ties
Line blocks Rebar (optional)
Buttering is a term used to describe the process of applying
Mason’s string Eye protection mortar to the end of a brick or block before adding it to the
3
⁄8" dowels structure being built. Apply a heavy layer of mortar to one end
of a brick, and then cut off the excess with a trowel.
■ How to Build a Double-layered Brick Wall
1 2
Dry-lay the first course by setting down two parallel rows Dampen the concrete slab or footing with water, and
of brick, spaced 3⁄4 to 1" apart. Use a chalk line to outline the dampen the bricks or blocks if necessary. Mix mortar and
location of the wall on the slab. Draw pencil lines on the slab to throw a layer of mortar on to the footing for the first two bricks
mark the ends of the bricks. Test-fit the spacing with a 3⁄8"-dia. of one wythe at one end of the layout. Butter the inside end of
dowel, and then mark the locations of the joint gaps to use as the first brick, and then press the brick into the mortar, creating
a reference after the spacers are removed. a 3⁄8" mortar bed. Cut away excess mortar.120 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
3 4 5
Plumb the face of the end brick using a Butter and place a third brick using Lay the first three bricks for the level. Tap lightly with the handle of the the chalk lines as a general reference, other wythe, parallel to the first wythe. trowel to correct the brick if it is not plumb. and then using a level to check for Level the wythes, and make sure the Level the brick end to end. Butter the end level and plumb. Adjust any bricks that end bricks and mortar joints align. Fill of a second brick, and then set it into the are not aligned by tapping lightly with the gaps between the wythes at each mortar bed, pushing the dry end toward the trowel handle. end with mortar. the first brick to create a joint of 3⁄8”.
6 7
Header
bricksCut a half brick, and then throw and furrow a mortar bed for Add more bricks and half bricks to both wythes at the end a half brick on top of the first course. Butter the end of the half until you lay the first bricks in the fourth course. Align bricks with brick, and then set the half brick in the mortar bed, creating a the reference lines. Note: To build corners, lay a header brick 3 ⁄8” joint. Cut away excess mortar. Make sure bricks are plumb at the end of two parallel wythes. Position the header brick and level. in each subsequent course perpendicular to the header brick in the previous course (inset).
(continued)
Brick & Block ■ 121
8 9
Check the spacing of the end bricks with a straightedge. Every 30 minutes, stop laying bricks and smooth out all
Properly spaced bricks will form a straight line when you place the untooled mortar joints with a jointing tool. Do the
the straightedge over the stepped end bricks. If bricks are horizontal joints first, and then the vertical joints. Cut away
not in alignment, do not move those bricks already set. Try to any excess mortar pressed from the joints using a trowel.
compensate for the problem gradually as you fill in the middle When the mortar has set, but is not too hard, brush any
(field) bricks (Step 11) by slightly reducing or increasing the excess mortar from the brick faces.
spacing between the joints.
10
Line block
Build the opposite end of the wall with the same methods as the first using the chalk lines as a reference. Stretch a mason’s
string between the two ends to establish a flush, level line between ends—use line blocks to secure the string. Tighten the string
until it is taut. Begin to fill in the field bricks (the bricks between ends) on the first course using the mason’s string as a guide.122 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
11 12
Metal
wall tieLay the remaining field bricks. The last brick, called In the fourth course, set metal wall ties into the mortar bed the closure brick, should be buttered at both ends. Center the of one wythe and on top of the brick adjacent to it. Space the closure brick between the two adjoining bricks, and then set ties 2 to 3 ft. apart, every three courses. For added strength, in place with the trowel handle. Fill in the first three courses set metal rebar into the cavities between the wythes and fill of each wythe, moving the mason’s string up one course after with thin mortar. completing each course.
13 14
Lay the remaining courses, installing metal ties every third Lay a furrowed mortar bed on the top course, and place a course. Check with mason’s string frequently for alignment, wall cap on top of the wall to cover empty spaces and provide and use a level to make sure the wall is plumb and level. a finished appearance. Remove any excess mortar. Make sure the cap blocks are aligned and level. Fill the joints between cap blocks with mortar.
Brick & Block ■ 123
■ Laying Block
B lock walls can be built fairly quickly because of
the size of the individual blocks. Still, the same
patience and attention to detail involved in laying bricks
is required. Check your work often, and don’t be afraid
to back up a step or two to correct your mistakes.
This section features a concrete block wall laid
up one course at a time. Make sure you have a sturdy,
level footing (page 46 to 49) before you start.
Tools & Materials ▸
Trowel Mortar mix
Chalk line 8 × 8" concrete blocks
Level Stakes
Mason’s string Cap blocks
Line blocks Rebar
Jointing tool Wire reinforcing strips
Stakes Scrap lumber
Work gloves Hammer
Buttering a concrete block involves laying narrow slices
Steel truss Chisel of mortar on the two flanges at the end of the block. It is not
Work braces necessary to butter the valley between the flanges unless the
project calls for it.
■ How to Lay a Concrete Block Wall
1 2
3"
3"
Dry-lay the first course, leaving a 3⁄8" gap between blocks. Dampen the base slightly, then mix mortar, and throw and
Draw reference lines on the concrete base to mark the ends of furrow two mortar lines at one end to create a mortar bed for
the row, extending the lines well past the edges of the block. the combination corner block. Dampen porous blocks before
Use a chalk line to snap reference lines on each side of the setting them into the mortar beds.
base, 3" from the blocks. These reference lines will serve as a
guide when setting the blocks into mortar.124 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
3 4
Set a combination corner block (page 110) into the mortar Drive a stake at each end of the project and attach one end bed. Press it into the mortar to create a 3⁄8”-thick bed joint. of a mason’s string to each stake. Thread a line level onto the Hold the block in place and cut away the excess mortar (save string and adjust the string until it is level and flush with the excess mortar for the next section of the mortar bed). Check top of the corner block. Throw a mortar bed and set a corner the block with a level to make sure it is level and plumb. Make block at the other end. Adjust the block so it is plumb and any necessary adjustments by rapping on the high side with the level, making sure it is aligned with the mason’s string. handle of a trowel. Be careful not to displace too much mortar.
5 6
Throw a mortar bed for the second block at one end of the Install all but the last block in the first course, working from project: Butter one end of a standard block and set it next to the ends toward the middle. Align the blocks with the mason’s the corner block, pressing the two blocks together so the joint string. Clean excess mortar from the base before it hardens. between them is 3⁄8” thick. Tap the block with the handle of a trowel to set it and adjust the block until it is even with the mason’s string. Be careful to maintain the 3⁄8” joint.
(continued)
Brick & Block ■ 125
7 8
Butter the flanges on both ends of a standard block for Apply a 1"-thick mortar bed for the half block at one end of
use as the closure block in the course. Slide the closure the wall, and then begin the second course with a half block.
block into the gap between blocks, keeping the mortar joints
an even thickness on each side. Align the block with the
mason’s string.
9
Vertical joints
Set the half block into the mortar bed with the smooth Variation: If your wall has a corner, begin the second course with
surfaces facing out. Use the level to make sure the half a full-sized end block that spans the vertical joint formed where
block is plumb with the first corner block, and then check to the two walls meet. This layout creates and maintains a running
make sure it is level. Adjust as needed. Install a half block at bond for the wall.
the other end.126 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
10 11
Attach a mason’s string for reference, securing it either with Every half-hour, tool the fresh mortar joints with a jointing line blocks or a nail. If you do not have line blocks, insert a nail into tool and remove any excess mortar. Tool the horizontal joints the wet mortar at each end of the wall, and then wind the mason’s first, and then the vertical joints. Cut off excess mortar using string around and up to the top corner of the second course, as a trowel blade. When the mortar has set, but is not too hard, shown above. Connect both ends and draw the mason’s string brush any excess mortar from the block faces. Continue taut. Throw a mortar bed for the next block, and then fill out the building the wall until it is complete. second course using the mason’s string as a reference line.
13Option: When building stack bond walls with vertical joints that are in alignment, use Install a wall cap on top of the wall to wire reinforcing strips in the mortar beds every third course (or as required by local cover the empty spaces and create a codes) to increase the strength of the wall. The wire should be completely embedded finished appearance. Set the cap pieces in the mortar. See page 114 for other block wall reinforcing options. into mortar beds, and then butter an end with mortar. Level the cap, and then tool to match the joints in the rest of the wall.
Brick & Block ■ 127
■ How to Build a Foundation Wall
1 2
Position story poles at each corner of the foundation. Lay the first course in a “dry run” to determine if you’ll need
Mark the top line using the string lines as reference, and then to cut or use any special blocks. Use a scrap piece 3⁄8" thick as
mark down 8" for each course of blocks. a spacer for the mortar joints.
3 4
Lay first block by spreading enough mortar for three blocks Set the opposite corner block in place and position mason
in a ladder pattern. Set corner block in place and check plumb line blocks and guide string. Follow the string in laying the rest
and level against story pole. of the course.128 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
5 6
As you build courses, tie supporting rebar to the footing Cut blocks as necessary, scoring on mark and breaking with rebar. Fill the rebar cavities with concrete. hammer and broad, cold chisel. You can also use a grinder equipped with a diamond blade.
7 8
Tool the mortar joints with a mason’s Provide additional lateral reinforcement by using steel truss work braces or jointer when the mortar is “thumbprint” “ladders” made to lay across the top of a course around the block cavities. These should ready. Sink anchor bolts for the mudsill be used every other course for best effect. Lastly, you can use special metal lath to into block cavities filled with concrete isolate a course and fill just that course with concrete—a requirement of some codes (inset). Space them roughly every 4 ft. for the top-most course.
Brick & Block ■ 129
Dry Block Wall Tools & Materials ▸
Aviation snips Mortar box
Mason’s trowel Line blocks
T he project shown here demonstrates how to lay a
mortarless concrete block wall that is coated with
surface-bonding cement. Surface-bonding cement
Brickset
Chisel
Concrete block
Metal ties
contains thousands of fiberglass fibers that interlock Maul Wire mesh
when the product cures, giving the wall greater Mason’s string Surface-bonding
flexural strength than an ordinary mortared block wall. Level cement
The finished appearance of walls coated with surface- Chalk line Stucco and mortar
bonding cement resembles stucco. It is ideal for Circular saw color (optional)
garden walls, stucco fence walls, trash can enclosures, Sprayer Eye protection and
mobile home skirting, and as a waterproof coating for Mortar work gloves
concrete ponds when used with acrylic fortifier.
Surface bonding cement gives a dry-stacked block wall an Moisten the blocks before applying the product.
attractive finished appearance. It also binds the blocks together.
■ How to Lay a Mortarless Block Wall
1 Wall
2
width
2x wall width
4"
Start with a dry layout of the first course on a concrete Mark the corners of the end blocks on the footing with a
footing. Where less than half a block is needed, trim two blocks pencil. Then, remove the blocks and snap chalk lines to indicate
instead. For example, where three and one-third block lengths where to lay the mortar bed and the initial course of block.
are required, use four blocks, and cut two of them to two-thirds
their length. You’ll end up with a stronger, more durable wall.130 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
3 4
Mist the footing with water, and then lay a 3⁄4”-thick bed of Lay the first course, starting at one end and placing blocks in mortar on the footing. Take care to cover only the area inside the mortar bed with no spacing in between. Use solid-faced blocks the reference lines. The mortar must be firm enough to prevent on the ends of the wall and check the course for level. If your the first course from sagging. wall is longer than 20 ft., consider inclusion of an expansion joint.
5 6 7
Half block
Line block
and stringLay subsequent courses one at a Mix the surface-bonding cement Apply surface-bonding cement in a time using a level to check for plumb thoroughly in a mortar box until it 1 ⁄4”-thick layer. Work from the bottom of and line blocks to check for level. Begin achieves a firm, workable consistency. the wall to the top. A variety of stucco courses with solid-faced blocks at each Eliminate all lumps during mixing. If you textures can be added to the wall as end. Use half blocks to establish a are coloring the surface bonding cement, soon as it becomes thumbprint hard. running-bond pattern. For walls over add the coloring agent directly to the 6 ft. tall, consult local building codes. mixing water prior to mixing the product.
Brick & Block ■ 131
Block Retaining Wall
R etaining walls are often used to level a yard or to
prevent erosion on a hillside. In a flat yard, you
can build a low retaining wall and fill in behind it to
Interlocking block weighs up to 80 pounds each,
so it is a good idea to have helpers when building a
retaining wall. Suppliers offer substantial discounts
create a raised planting bed. when interlocking block is purchased in large quantities,
While retaining walls can be built from many so you may be able to save money if you coordinate
materials, such as pressure-treated timbers and natural your own project with those of your neighbors.
stone, interlocking blocks are common. Typically The retaining walls in this section were built
made from concrete, interlocking retaining wall blocks with either interlocking block or cut stone. These
are rather inexpensive, very durable, and DIY friendly. durable materials are easy to work with. No matter
Several styles of interlocking block are available at what material you use, your wall can be damaged
building centers and landscape materials suppliers. if water saturates the soil behind it, so make sure
Most types have a natural rock finish that combines you include the proper drainage features. You may
the rough texture of cut stone with the uniform shape need to dig a drainage swale before building in low-
and size of concrete blocks. lying areas.
Tools & Materials ▸
Wheelbarrow Masonry chisel Tape measure Perforated drain pipe
Shovel Eye protection Marking pencil Coarse backfill
Garden rake Hearing protectors Caulk gun material
Line level Work gloves Stakes Construction adhesive
Hand tamper Circular saw with Mason’s string Retaining wall block
Tamping machine masonry-cutting blade Landscape fabric Cap blocks
Small maul Level Compactable gravel Spraypaint
Terraced retaining walls work well on steep hillsides. Two or more short retaining walls are easier to install and more stable than
a single, tall retaining wall. Construct the terraces so each wall is no higher than 3 ft.132 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Options for Positioning a Retaining Wall Structural Features ▸ Y ou can add more level ground to your yard by how you position a retaining wall. To increase the level area above the wall, position it well forward from The “guts” of a retaining wall are its structural features: a compactable gravel sub-base to make a the top of the hill. Fill in behind the wall with extra solid footing for the wall; crushed stone backfill and a soil. Maintain the shape of your yard by positioning perforated drain pipe to improve drainage behind the the wall near the top of the hillside, and use soil wall; and landscape fabric to keep the loose soil from removed at the base of the hill to fill in behind the washing into and clogging the gravel backfill. top of the wall.
A B Landscape Soil removed from fabric base of hill Original hillside
Gravel backfill Extra soil
Compactable Compactable gravel gravel sub-base sub-base
Original hillsideIncrease the level area above the wall (A) by positioning the wall well forward from the top of the hill. Fill in behind the wall with extra soil, which is available from sand-and-gravel companies. Keep the basic shape of your yard (B) by positioning the wall near the top of the hillside. Use the soil removed at the base of the hill to fill in near the top of the wall.
Building Retaining Walls ▸
Backfill with crushed stone and install a perforated drain Make a stepped trench when the ends of a retaining
pipe about 6” above the bottom of the backfill. Vent the pipe wall must blend into an existing hillside. Retaining walls
to the side or bottom of the retaining wall, where runoff water often are designed so the ends curve or turn back into
can flow away from the hillside without causing erosion. the slope.
Brick & Block ■ 133
■ How to Build a Retaining Wall Using Interlocking Block
Interlocking wall blocks do not need
Overlapping mortar. Some types are held together
flanges with a system of overlapping flanges
that automatically set the backward
pitch (batter) as the blocks are stacked,
as shown in this project. Other types of
Crushed stone
backfill
blocks use fiberglass pins (inset).
First row
installed
upside down
Pins
Perforated
drain pipe
Compactable
gravel sub-base
Landscape
fabric
1 2 3
Excavate the hillside, if necessary. Dig out the bottom of the excavation Line the excavation with strips of
Allow 12" of space for crushed stone below ground level, so it is 6" lower than landscape fabric cut 3 ft. longer than the
backfill between the back of the wall the height of the block. For example, if planned height of the wall. Make sure all
and the hillside. Use stakes to mark you use 6"-thick block, dig down 12". seams overlap by at least 6".
the front edge of the wall. Connect the Measure down from the string to make
stakes with mason’s string, and use a sure the bottom base is level.
line level to check for level.134 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
4 5
Spread a 6” layer of compactable gravel over the bottom of Lay the first course of block, aligning the front edges with the excavation as a sub-base and pack it thoroughly. A rented the mason’s string. (When using flanged block, place the first tamping machine, or jumping jack, works better than a hand course upside down and backward.) Check frequently with a tamper for packing the sub-base. level, and adjust, if necessary, by adding or removing sub-base material below the blocks.
6 7
Lay the second course of block according to Make half-blocks for the corners and ends of a wall and manufacturer’s instructions, checking to make sure the blocks use them to stagger vertical joints between courses. Score full are level. (Lay flanged block with the flanges tight against the blocks with a circular saw and masonry blade, and then break underlying course.) Add 3 to 4” of gravel behind the block, and the blocks along the scored line with a maul and chisel. pack it with a hand tamper.
(continued)
Brick & Block ■ 135
8 9
Add and tamp crushed stone, as needed, to create a slight Fill behind the wall with crushed stone, and pack it
downward pitch (about 1⁄4" of height per foot of pipe) leading thoroughly with the hand tamper. Lay the remaining courses
to the drain pipe outlet. Place the drain pipe on the crushed of block, except for the cap row, backfilling with crushed stone
stone, 6" behind the wall, with the perforations face down. and packing with the tamper as you go.
Make sure the pipe outlet is unobstructed. Lay courses of
block until the wall is about 18" above ground level, staggering
the vertical joints.
10 11
Before laying the cap block, fold the end of the landscape Apply construction adhesive to the top course of block,
fabric over the crushed stone backfill. Add a thin layer of and then lay the cap block. Use topsoil to fill in behind the
topsoil over the fabric, and then pack it thoroughly with a wall and to fill in the base at the front of the wall. Install sod or
hand tamper. Fold any excess landscape fabric back over the plants as desired.
tamped soil.136 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Add a Curve to an Interlocking Block Retaining Wall 1 2
Right angleOutline the curve by first driving a stake at each end and Excavate for the wall section, following the curved layout then driving another stake at the point where lines extended line. To install the first course of landscape blocks, turn them from the first stakes would form a right angle. Tie a mason’s upside down and backwards and align them with the radius string to the right-angle stake, extended to match the distance curve. Use a 4-ft. level to ensure the blocks sit level and are to the other two stakes, establishing the radius of the curve. properly placed. Mark the curve by swinging flour or spray paint at the string end, like a compass.
3 4
Install subsequent courses so the overlapping flange sits flush against the back Use half blocks or cut blocks to create of the blocks in the course below. As you install each course, the radius will change finished ends on open ends of the wall. because of the backwards pitch of the wall, affecting the layout of the courses. Where necessary, trim blocks to size. Install using landscape construction adhesive, taking care to maintain the running bond.
Brick & Block ■ 137
The structure is freestanding and self-supporting, so
Outdoor Kitchen it can go almost anywhere—on top of a patio, right
next to a house wall, out by the pool, or out in the yard
to create a remote entertainment getaway. Adding a
W ith its perfect blend of indoor convenience
and alfresco atmosphere, it’s easy to see
why the outdoor kitchen is one of today’s most
table and chairs or a casual sitting area might be all
you need to complete your kitchen accommodations.
But best of all, this kitchen is made almost entirely of
popular home upgrades. In terms of design, outdoor inexpensive masonry materials.
kitchens can take almost any form, but most are Concrete and masonry are ideally suited to outdoor
planned around the essential elements of a built-in kitchen construction. Both are noncombustible, not
grill and convenient countertop surfaces (preferably damaged by water, and can easily withstand decades
on both sides of the grill). Secure storage inside the of outdoor exposure. In fact, a little weathering makes
cooking cabinet is another feature many outdoor masonry look even better. In this project, the kitchen’s
cooks find indispensable. structural cabinet is built with concrete block on top of
The kitchen design in this project combines all a reinforced concrete slab. The countertop is two-inch-
three of these elements in a moderately sized cooking thick poured concrete that you cast in place over two
station that can fit a variety of kitchen configurations. layers of cementboard.
Tools & Materials ▸
Chalk line Utility knife Concrete block Silicone caulk
Pointing trowel Straightedge Reinforcing wire or Stucco lath
Masonry mixing tools Square-notched trowel rebar Vegetable oil or other
Level Metal snips Hammer release agent
Mason’s string Wood float Metal reinforcement Concrete mix
Circular saw with Steel trowel Steel angle iron Base coat stucco
masonry blade Drill with masonry bit 1
⁄2" cementboard Finish coat stucco
Eye protection and Mortar mix or Lumber (2 × 4, 2 × 6) Sealer
work gloves mason mix Deck screws (21⁄2, 3") Sandpaper
This practical outdoor kitchen has just what the serious griller needs—a built-in grill and plenty of countertop space for preparing
and serving meals. At just over 8 ft. long and about 3 ft. wide, the kitchen can fit almost anywhere on a standard concrete patio.138 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Construction Details T he basic structure of this kitchen consists of five courses of standard 8 × 8 × 16” concrete block. Two mortared layers of 1⁄2” cementboard serve that can be tinted during the mixing or painted after it cures. Doors in the front of the cabinet provide access to storage space inside and to any utility as a base for the countertop. The 2”-thick poured connections for the grill. The kitchen’s dimensions concrete layer of the countertop extends 11⁄2” beyond can easily be adjusted to accommodate a specific the rough block walls and covers the cementboard location, cooking equipment, or doors and additional edges. The walls receive a two-coat stucco finish amenities.
Plan view 99"
Grill and door
placements Grill Concrete countertop
vary by product 35" poured over 2 layers 32" 9 × 9 × 16"
of 1⁄ 2" cementboard concrete block
Stucco (approx. 1⁄ 2"
Door Double doors total thickness)
Front elevation Grill
1"
1" overhang
(beyond)
35" stucco)
Door Door
Concrete slab
(reinforced as
required)
Planning an Outdoor Kitchen Project ▸
Whether you model your project after the one shown here
or create your own design, there are a few critical factors
to address as part of your initial planning:
Foundation: Check with your local building department
about foundation requirements for your kitchen.
Depending on the kitchen’s size and location, you may
be allowed to build on top of a standard four-inch-thick
reinforced concrete patio slab, or you might need frost A grill gas line typically extends up into the cabinet
footings or a reinforced “floating footing” similar to the space under the grill and is fitted with a shutoff valve.
one shown on page 148 (Brick Barbecue).
Utility hookups: Grills fueled by natural gas require a
Grill and door units: You’ll need the exact dimensions plumbed gas line, and those with electric starters need
of the grill, doors, and any other built-in features before an outdoor electrical circuit, both running into the kitchen
you draw up your plans and start building. When shopping cabinet. To include a kitchen sink, you’ll need a dedicated
for equipment, keep in mind its utility requirements and water line and a drain connection (to the house system,
the type of support system needed for the grill and other directly to the city sewer, or possibly to a dry well on
large units. Some grills are drop-in and are supported only your property). Outdoor utilities are strictly governed by
by the countertop; others must be supported below with building codes, so check with the building department for
a noncombustible, load-bearing material such as concrete requirements. Generally, the rough-in work for utilities is
block or a poured concrete platform. best left to professionals.
Brick & Block ■ 139
■ How to Build an Outdoor Kitchen
1 2
Pour the foundation or prepare the slab for the wall Dry-lay the first course of block on the foundation to test
construction. See pages 46 to 49 for help with building frost the layout. If desired, use 2- or 4"-thick solid blocks under the
footings and pages 68 to 71 for pouring a concrete slab. To door openings. Snap chalk lines to guide the block installation,
prepare an existing slab, clean the surface thoroughly to and mark the exact locations of the door openings.
remove all dirt, oils, concrete sealers, and paint that could
prevent a good bond with mortar.
3 4
Set the first course of block into mortar, following the basic Continue laying up the wall, adding reinforcing wire or
techniques shown on pages 124 to 127. Cut blocks as needed rebar if required by local building code. Instead of tooling the
for the door openings. Lay the second course, offsetting the mortar joints for a concave profile, use a trowel to slice excess
joints with the first course in a running-bond pattern. mortar from the blocks. This creates a flat surface that’s easier
to cover with stucco.140 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
5
Install steel angle lintels to span over the door openings. If an opening is in line with a course of block, mortar the lintels in place on top of the block. Otherwise, use a circular saw with a masonry blade to cut channels for the horizontal leg of the angle. Lintels should span 6” beyond each side of an opening. Slip the lintel into the channels, and then fill the block cells containing the lintel with mortar to secure the lintel in place. Lay a bed of mortar on top of the lintels, and then set block into the mortar. Complete the final course of block in the cabinet and let the mortar cure.
6 7
Cut two 8-ft.-long sheets of cementboard to match Cut pieces to fit for a second layer of cementboard. Apply the outer dimensions of the block cabinet. Apply mortar a bed of mortar to the top of the first panel and then lay the to the tops of the cabinet blocks and then set one layer of second layer pieces on top, pressing them into the mortar so cementboard into the mortar. If you will be installing a built-in the surfaces are level. Let the mortar cure. grill or other accessories, make cutouts in the cementboard with a utility knife or a jigsaw with a remodeler’s blade.
(continued)
Brick & Block ■ 141
8 9
To create a 11⁄2" overhang for the countertop, build a Cut vertical 2 × 4 supports to fit snugly between the
perimeter band of 2 × 4 lumber; this will serve as the base foundation and the bottom of the 2 × 4 band. Install a support
of the concrete form. Cut the pieces to fit tightly around the at the ends of each wall and evenly spaced in between. Secure
cabinet along the top. Fasten the pieces together at their ends each support with angled screws driven into the band boards.
with 3" screws so their top edges are flush with the bottom of
the cementboard.
10 11
Build the sides of the countertop Form the opening for the grill using 2 × 6 side pieces (no overhang inside
form with 2 × 6s cut to fit around the opening). Support the edges of the cementboard along the grill cutout with cleats
2 × 4 band. Position the 2 × 6s so attached to the 2 × 6s. Add vertical supports as needed under the cutout to keep the
their top edges are 2" above the form from shifting under the weight of the concrete.
cementboard and fasten them to the
band with 21⁄2" screws.142 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
12 13
Cut a sheet of stucco lath to fit into the countertop form, leaving a 2” space along Dampen the cementboard with a mist the inside perimeter of the form. Remove the lath and set it aside. Seal the form joints of water. Mix a batch of countertop mix, with a fine bead of silicone caulk and smooth with a finger. After the caulk dries, coat adding color if desired (see page 104). the form boards (not the cementboard) with vegetable oil or other release agent. Working quickly, fill along the edges of the form with concrete, carefully packing it down into the overhang portion by hand.
14 15
Fill the rest of the form halfway up with an even layer of Tap along the outsides of the form with a hammer to concrete. Lay the stucco lath on top, and then press it lightly remove air bubbles trapped against the inside edges. Screed into the concrete with a float. Add the remaining concrete so the top of the concrete with a straight 2 × 4 riding along the it’s flush with the tops of the 2 × 6s. form sides. Add concrete as needed to fill in low spots so the surface is perfectly flat.
(continued)
Brick & Block ■ 143
16 17 18
After the bleed water disappears, A few hours after floating, finish the Moist-cure the countertop with a fine
float the concrete with a wood or countertop as desired. A few passes water mist for three to five days. Remove
magnesium float. The floated surface with a steel finishing trowel yields the the form boards. If desired, smooth the
should be flat and smooth but will still smoothest surface. Hold the leading countertop edges with an abrasive brick
have a somewhat rough texture. Be edge of the trowel up and work in and/or a diamond pad or sandpaper.
careful not to overfloat and draw water circular strokes. Let the concrete set for After the concrete cures, apply a food-
to the surface. a while between passes. safe sealer to help prevent staining.
19 20
Prepare for door installation in the cabinet. Outdoor
cabinet doors are usually made of stainless steel and typically
are installed by hanging hinges or flanges with masonry
anchors. Drill holes for masonry anchors in the concrete block,
following the door manufacturer’s instructions.
Quick Tip ▸
Honeycombs or air voids can be filled using a cement
Finish installing and hanging the doors. Test the door
slurry of cement and water applied with a rubber float.
operations and make sure to caulk around the edges with
If liquid cement color was used in your countertop
high-quality silicone caulk. Note: Doors shown here are
concrete mix, color should be added to the wet cement best installed before the stucco finish is applied to the
paste. Some experimentation will be necessary. cabinet. Other doors may be easier to install following a
different sequence.144 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
21
To finish the cabinet walls, begin by dampening the contrete block and then applying a 3⁄8”-thick base coat of stucco, following the steps on pages 250 to 255. Apply an even layer over the walls; then smooth the surface with a wood float and moist-cure the stucco for 48 hours or as directed by the manufacturer.
22 23
Apply a finish coat of tinted stucco that’s at least 1⁄8” thick. Set the grill into place, make the gas connection, and Evenly saturate the base coat stucco surface with water prior then check it carefully for leaks. Permanently install the grill to applying the the finish coat. Texture the surface as desired. following the manufacturer’s directions. The joints around grills Moist-cure the stucco for several days as directed. are highly susceptible to water intrusion; seal them thoroughly with an approved caulk to help keep moisture out of the cabinet space below.
Brick & Block ■ 145
Brick Barbecue Mortar Data ▸
Type N Mortar: Nonstructural mortar for veneer
applications, reaches 750 psi @ 28 days
T he barbecue design shown here is constructed with
double walls—an inner wall, made of heat-resistant
fire brick set on edge, surrounding the cooking area, Type S Mortar: Structural mortar for veneer
structural applications, exceeds 1,800 psi @ 28 days
and an outer wall, made of engineer brick. We chose
this brick because its larger dimensions mean you’ll
have fewer bricks to lay. You’ll need to adjust the design
if you select another brick size. A four-inch air space
between the walls helps insulate the cooking area. The The foundation combines a 12-inch-deep
walls are capped with thin pieces of cut stone. footing supporting a reinforced slab. This structure,
Refractory mortar is recommended for use in areas known as a floating footing, is designed to shift as a
of direct fire contact. It is heat resistant and the joints unit when temperature changes cause the ground to
will last a long time without cracking. Ask a local brick shift. Ask a building inspector about local building
yard to recommend a refractory mortar for outdoor use. code specifications.
Tools & Materials ▸
Tape measure Shovel 18-gauge galvanized Metal ties
Hammer Wood float metal mesh 4" tee plates
Brickset chisel Chalk line #4 rebar Brick sealer
Mason’s string Level 16-gauge tie wire Stainless-steel
Shovel Wheelbarrow Bolsters expanded mesh
Aviation snips Mason’s trowel Fire brick Cooking grills
Reciprocating saw Jointing tool Engineer brick Ash pan
or hacksaw Garden stakes Type N or Type S mortar Concrete mix
Masonry hoe 2 × 4 lumber 3
⁄8"-dia. dowel Work gloves
The addition of a brick barbecue
to your patio is a non-intrusive way to
incorporate summer cooking into a four-
seasons space, while adding the beauty
and stability of brick to your outdoor
decorating scheme.146 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Pouring a Floating Footing ▸
Garden stake
Mason’s string
Form
Ground level
6"
#4 rebar
10"
6" 12"
5'
Lay out a 4 × 5-ft. area. Dig a continuous trench 12" wide × footing with five 52"-long pieces of rebar. Use a mason’s
10" deep along the perimeter of the area, leaving a string and a line level to ensure that the forms are level
rectangular mound in the center. Remove 4" of soil from from side to side. Set the rebar on the bolster 4" from the
the top of the mound, and round over the edges. Set a front and rear sides of the trench, centered from side to
2 × 4 form around the site so that the top is 2" above the side. Space the remaining three bars evenly in between.
ground along the back and 11⁄2" above the ground along Coat the forms with vegetable oil or release agent and
the front. This slope will help shed water. Reinforce the pour the concrete.■ How to Build a Brick Barbecue 1 2
After the footing has cured for one week, use a chalk line to Dry-lay the first course of fire brick around the outside of mark the layout for the inner edge of the fire brick wall. Make the rectangle, allowing for 1⁄8”-thick mortar joints. Note: Proper a line 4” in from the front edge of the footing and a center line placement of the inner walls is necessary so they can support perpendicular to the first line. Make a 24 × 32” rectangle that the grills. Start with a full brick at the 4” line to start the right starts at the 4” line and is centered on the center line. and left walls. Complete the course with a cut brick in the middle of the short wall. (continued)
Brick & Block ■ 147
3 4
Dry-lay the outer wall, as shown here, using 4 × 31⁄5 × 8" Make a story pole. On one side, mark 8 courses of fire brick,
nominal engineer brick. Gap the bricks for 3⁄8" mortar joints. The leaving a 3⁄8" gap for the bottom mortar joint and 1⁄8" gaps for
rear wall should come within 3⁄8" of the last fire brick in the left the remaining joints. The top of the final course should be 36"
inner wall. Complete the left wall with a cut brick in the middle from the bottom edge. Transfer the top line to the other side of
of the wall. Mark reference lines for this outer wall. the pole. Lay out 11 courses of engineer brick, spacing them
evenly so that the final course is flush with the 36" line. Each
horizontal mortar joint will be slightly less than 1⁄2" thick.
5 6 7
Lay a bed of mortar for a 3⁄8" joint along Lay the first course of the outer wall, Start the second course of the outer
the reference lines for the inner wall, and using Type N or Type S mortar. Use oiled wall using a half-brick butted against
then lay the first course of fire brick using 3
⁄8” dowels to create weep holes behind each side of the inner wall, and then
1
⁄8" joints between the bricks. the front bricks of the left and right complete the course. Because there is
walls. Alternate laying the inner and a half-brick in the right outer wall, you
outer walls, checking your work with the need to use two three-quarter bricks in
story pole and a level after every course. the second course to stagger the joints.148 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
8 9
Place metal ties between the corners of the inner and outer Smooth the mortar joints with a jointing tool when the walls at the second, third, fifth, and seventh courses. Use ties mortar has hardened enough to resist minimal finger pressure. at the front junctions and along the rear walls. Mortar the joint Check the joints in both walls after every few courses. The where the left inner wall meets the rear outer wall. different mortars may need smoothing at different times.
10 11
Add tee plates for grill supports above the fifth, sixth, and When both walls are complete, install the capstones. Lay seventh courses. Use 4”-wide plates with flanges that are no a bed of Type N or Type S mortar for a 3⁄8”-thick joint on top more than 3⁄32” thick. Position the plates along the side fire of the inner and outer walls. Lay the capstone flat across the brick walls, centered 3”, 12”, 18”, and 27” from the rear fire walls, keeping one end flush with the inner face of the fire brick wall. brick. Make sure the bricks are level and tool the joints when they are ready. After a week, seal the capstones and the joints between them with brick sealer and install the grills.
Brick & Block ■ 149
Brick Planter
B rick is the masonry material of choice for
elegant entry planters. It also complements
a brick-paver landing. For a foundation for the
structures, such as a landing or house foundation,
by isolation joints. With larger planter projects,
a frost footing often is required; check your local
planter, pour a slab that is separated from adjacent building code.
Tools & Materials ▸
Mason’s string Bricks
Line level Screws
Drill 1 × 4 lumber
Level Stakes
Shovel 1 × 4 concrete
Rake step forms
Hoe Pavers
Wheelbarrow Compactable gravel
Hand tamper 3
⁄8"-dia. copper or
Rubber mallet PVC tubing
Jointing tool Sand
Tape measure Isolation board
Broom Cap bricks
Mason’s trowel Landscape fabric
Your planter can capture the rustic beauty of an antique trough Type S mortar Work gloves
or dress up a brick entryway.
■ How to Build a Brick Planter
1 2
Excavate the building site, install forms and isolation Test-fit the first course of the project, and then outline the
boards, and pour a concrete base for the project. Let the project on the concrete surface. Dampen the surface slightly
foundation cure for three days before building on it. Remove then mix mortar and throw a mortar bed in one corner (pages
forms, and then trim isolation boards so they are level with 118 to 121). Begin laying bricks for the project, buttering the
the tops of adjoining structures, like the landing shown above. exposed end of each brick before setting it.
Tip: Cover adjoining surfaces for protection.150 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
3 4 Corner return bricks Weep-hole tubes
Lay one section of the first course, checking the bricks Install weep holes for drainage in the first course of bricks frequently with a level to make sure the tops are level and on the sides farthest away from permanent structures. Cut even. Lay two corner return bricks perpendicular to the end 3 ⁄8”-dia. copper or PVC tubing about 1⁄4” longer than the width bricks in the first section and use a level to make sure they are of one brick and set the pieces into the mortar joints between even across the tops. bricks, pressing them into the mortar bed so they touch the footing. Make sure mortar doesn’t block the openings.
5 6
Finish building all sides of the first course. Lay the Install cap bricks to keep water from entering the cores of second course of bricks, reversing the directions of the corner the brick and to enhance the visual effect. Set the cap bricks bricks to create staggered vertical joints if using a running- into a 3⁄8”-thick mortar bed, buttering one end of each cap bond pattern. Fill in brick courses to full height, building up one brick. Let the mortar cure for one week. Before adding soil, course at a time. Check frequently to make sure the tops of the pour a 4 to 6”-thick layer of gravel into the bottom of the bricks are level and sides are plumb. planter for drainage, and then line the bottom and sides of the planter with landscape fabric to prevent dirt from running into and clogging the drainage tubes.
Brick & Block ■ 151
Brick Pillars
D ecorative pillars are easy to design because you don’t
have to be concerned about the seasonal shifting of
attached brick or stone walls. We designed a pair of
12 × 16” pillars using only whole bricks, so you don’t
need to worry about splitting or cutting. These pillars
are refined in appearance but sturdy enough to last
for decades.
Once the last course of bricks is in place, you
can add a brick or stone cap for a finished look.
Or, build two pillars connected by an arch (pages
156 to 159). If you’re planning an arch, consider
attaching hardware for an iron gate. It’s far easier to
place the hardware in fresh mortar, so make a note
of the brick courses where the hardware will go. The
settings will look cleaner this way and the hardware
will stay secure for a long time.
Tools & Materials ▸
Level Pointing chisel
Bricklayer’s trowel Dowel
Jointing tool Type N mortar mix
Aviation snips 1
⁄4" wire mesh
Wheelbarrow Capstone or
Shovel concrete cap
Hoe Lumber (1 × 3,
This 4-ft. pillar was built with 18 courses of brick. A brick cap
Tape measure 2 × 2) adds a touch of elegance and protects against rain, ice, and
Standard modular 3
⁄8"-thick wood scraps snow. You can also build pillars with stone caps, or, as shown
bricks (4 × 22⁄3 × 8") Work gloves on the following pages, use cast concrete caps, which are
available in many sizes.
Pour footings that are 4" longer and
wider than the pillars on each side. This
project calls for 16 × 20" footings.152 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Building Brick Pillars ▸
Use a story pole to maintain consistent mortar joint Cut a straight 2 × 2 to fit tight in the space between the
thickness. Line up a scrap 1 × 2 on a flat tabletop alongside two pillars. As you lay each course for the second pillar,
a column of bricks, spaced 3⁄8" apart. Mark the identical use the 2 × 2 to check the span.
spacing on the 1 × 2. Hold up pole after every few courses
to check the mortar joints for consistent thickness.■ How to Build Brick Pillars 1 2
Once the footing has cured, dry-lay the first course of five Lay a bed of mortar inside the reference lines and lay the bricks, centered on the footing. Mark reference lines around first course. the bricks.
(continued)
Brick & Block ■ 153
3 4
Use a pencil or dowel coated with vegetable oil to create a Lay the second course, rotating the pattern 180º. Lay
weep hole in the mortar in the first course of bricks. The hole additional courses, rotating the pattern 180º with each course.
ensures drainage of any moisture that seeps into the pillar. Use the story pole and a level to check each face of the pillar
after every other course. It’s important to check frequently, since
any errors will be exaggerated with each successive course.
5 6
After every fourth course, cut a strip of 1⁄4" wire mesh and After every five courses, use a jointing tool to smooth
place it over a thin bed of mortar. Add another thin bed of mortar the joints that have hardened enough to resist minimal
on top of the mesh, and then add the next course of brick. finger pressure.154 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
7 8
For the final course, lay the bricks over a bed of mortar and Build the second pillar in the same way as the first. Use the wire mesh. After placing the first two bricks, add an extra brick story pole and measuring rod to maintain identical dimensions in the center of the course. Lay the remainder of the bricks and spacing. around it. Fill the remaining joints, and work them with the jointing tool as soon as they become firm.
■ How to Install a Cap Stone 1 2
Select a capstone 3” longer and wider Spread a 1⁄2”-thick bed of mortar on top of the pillar. Center the cap on the pillar than the top of the pillar. Mark reference using the reference lines. Strike the mortar joint under the cap so it’s flush with the lines on the bottom for centering the pillar. Note: If mortar squeezes out of the joint, press 3⁄8”-thick wood scraps into the cap. Do not install caps if you are adding mortar at each corner to support the cap. Remove the scraps after 24 hours and fill in an arch to your pillars. the gaps with mortar.
Brick & Block ■ 155
Brick Archway
B uilding an arch over a pair of pillars is a
challenging task made easier with a simple,
semi-circular plywood form. With the form in place,
Tools & Materials ▸
you can create a symmetrical arch by laying bricks Hammer Jointing tool
along the form’s curved edge. Select bricks equal in Joint chisel Tuck-pointer
length to those used in the pillars. Mason’s hammer 3
⁄4" plywood
Brick or concrete archways were very common Pry bar 1
⁄4" plywood
during the Roman Empire, when clever engineers Jigsaw Wallboard screws
devised ways to leverage geometry in their favor Circular saw (1 and 2")
while constructing baths, aqueducts, and many other Drill Bricks
masonry structures. The principles are so sound and Compass Type N mortar mix
the materials so durable that many ancient archways Level 2 × 4 and 2 × 8 lumber
remain standing today. Mason’s string Shims
Trowel Work gloves
If you’re building an arch over existing pillars, measure the distance between the pillars at several points. The span must be the
same at each point in order for the pillars to serve as strong supports for your arch.156 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Build a Form for an Arch ▸
1. Determine the distance between the inside edges of
2 × 4 brace
the tops of your pillars. Divide the distance in half and
1
⁄4" plywood
then subtract 1⁄4”. Use this as the radius in Step 2.
2. Mark a point at the center of a sheet of 3⁄4” plywood.
Use a pencil and a piece of string to scribe a circle on
the plywood using the radius calculated in Step 1. Cut
out the circle with a jigsaw. Mark a line through the
center point of the circle and cut the circle in half.
3. Construct the form by bracing the two semicircles 3
⁄4" plywood
using 2” wallboard screws and 2 × 4s. To calculate
the length of the 2 × 4 braces, subtract the combined
thickness of the plywood sheets —11⁄2”—from the shims
width of the pillars and cut the braces to length. Cover 2" wallboard
the top of the form with 1⁄4” plywood, attached with 1” screw
1" wallboard
wallboard screws. screw■ How to Build a Brick Arch 1 2 3
Tip: If your pillars are capped, remove To determine brick spacing, start Place the compass point on this the caps before building an arch. Chip by centering a brick at the peak and new mark and make another mark out the old mortar from underneath placing a compass point at one edge. along the curve. Continue making using a hammer and joint chisel. With a With the compass set to the width of marks along the curve until less than helper nearby to support the cap, use a one brick plus 1⁄4”, mark the form with a brick’s width remains. pry bar and shims to remove each cap the pencil. from the pillar.
(continued)
Brick & Block ■ 157
4 5
Divide this remaining width by the number of compass Cut two 2 × 8 braces 1⁄2" shorter than pillar height and prop
marks and increase the compass setting by this amount. Using one against each pillar with 2 × 4 cross braces. Place shims on
a different color, make final reference marks to either side of top of each 2 × 8 to raise the form so its bottom is even with
the peak. Extend the pencil lines across the curved surface of the tops of the pillars. Rest the plywood form on the braces.
the form and onto the far edge.
6 7
Mix mortar and trowel a narrow 3⁄8" layer on top of one Place five bricks, and then tack a string to the center point
pillar. Place one brick, and then rap the top with a trowel of the form on each side and use the strings to check each
handle to settle it. Butter the bottom of each subsequent brick brick’s alignment. Take care not to dislodge other bricks as you
and place it in position. tap a brick into position.158 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
8 9 10
To balance the weight on the form, Butter the center, or keystone, brick Lay a bed of mortar over the first switch to the other side. Continue as accurately as possible and ease it course and then lay the second course alternating until space for one brick into place. Smooth the remaining joints halfway up each side, maintaining the remains. Smooth previous joints with a with a jointing tool. same mortar joint thickness as in the jointing tool as they become firm. first layer. Some of the joints will be staggered, adding strength to the arch.
11 12
Dry-lay several more bricks on one side—using shims as substitutes for mortar Leave the form in place for a week, joints—to check the amount of space remaining. Remove the shims and lay the final misting occasionally. Carefully remove bricks with mortar, and then smooth the joints with a jointing tool. the braces and form. Tuck-point and smooth the joints on the underside of the arch.
Brick & Block ■ 159
Windowsill
Brick Wall Veneer
Sill extension
B rick veneer is essentially a brick wall built around
the exterior walls of a house. It’s attached to the
house with metal wall ties and supported by a metal
shelf hanger on the foundation. It’s best to use queen-
Rowlock brick
sized bricks for veneer projects because they’re thinner
than standard construction bricks. This means less
weight for the house walls to support. Even so, brick
Field bricks
veneer is quite heavy. Ask your local building inspector
about building code rules that apply to your project. In
the project shown here, brick veneer is installed over
the foundation walls and side walls, up to the bottom
of the windowsills on the first floor of the house. The
siding materials in these areas are removed before 1
⁄ 2" gap
installing the brick.
Construct a story pole before you start laying the
brick so you can check your work as you go along to
Building
be sure your mortar joints are of a consistent thickness. paper
A standard three-eighths-inch gap is used in the
project shown here.
Sheathing
Tools & Materials ▸
Corrugated
wall tie
Pencil Mason’s string Rim joist
Hammer Silicone caulk
Circular saw 2×2 Weep-hole
Combination square Lead sleeve anchors rope
Level Angle iron for metal
Drill with shelf supports Sill plate
masonry bit 30-mil PVC roll
Socket wrench set flashing
PVC flashing
Staple gun Corrugated metal
Mason’s trowel wall ties
Masonry hoe Brickmold for sill Ground
level
Mortar box extensions
Mason’s chisel Sill-nosing trim
Maul Type N mortar
Pressure-treated Bricks Metal shelf
hanger
2 × 4s 3
⁄8”-dia. cotton rope
3
⁄8 × 4” lag screws Work gloves and eye
and washers protection Foundation
wall
10d Nails
Anatomy of a brick veneer facade: Queen-sized bricks are
stacked onto a metal or concrete shelf and connected to the
foundation and walls with metal ties. Rowlock bricks are cut to
follow the slope of the windowsills, and then laid on edge over
the top course of bricks.160 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Install Brick Veneer 1 2 3 Story pole
Top-
course
Sill extension line
Top-
course
line
Ground levelRemove all siding materials in the Precut the bricks to follow the slope of Make a story pole long enough to area you plan to finish with brick veneer. the sill and overhang the field brick by 2”. span the project area. Mark the pole Before laying out the project, cut the sill Position this rowlock brick directly under with 3⁄8” joints between bricks. Dig a extension from a pressure-treated 2 × 4. the sill extension. Use a combination 12”-wide, 12”-deep trench next to the Tack the extension to the sill temporarily. square or level to transfer the lowest wall. Position the pole so the top-course point on the brick onto the sheathing line on the sheathing aligns with a top (marking the height for the top course of mark for a brick on the pole. Mark a line brick in the field). Use a level to extend for the first course on the wall, below the line. Remove the sill extensions. ground level.
4 5 Web locations (solid)
Masonry
anchorExtend the mark for the first-course height across the Set the metal shelf onto the temporary supports. Mark the foundation wall using a level as a guide. Measure the thickness location of the center web of each block onto the vertical face of of the metal shelf (usually 1⁄4”) and drill pilot holes for 10d nails the shelf. Remove the shelf and drill 3⁄8”-dia. holes for lag screws at into the foundation at 16” intervals along the first-course line, far the web marks. Set the shelf back onto the temporary supports and enough below the line to allow for the thickness of the shelf. Slip outline the predrilled holes on the blocks. Remove the shelf and drill nails into the pilot holes to create temporary support for the shelf. holes for the masonry anchors into the foundation using a masonry bit. Drive masonry anchors into the holes.
(continued)
Brick & Block ■ 161
6 7 8
Expansion joint
Reposition the shelf on the supports Staple 30-mil PVC flashing above the Test-fit the first course on the shelf.
so the predrilled holes align with the foundation wall after all sections of the Work in from the ends, using spacers
masonry anchors. Attach the shelf to metal shelf are attached. Be sure the to set the gaps between bricks. You
the foundation wall with 3⁄8 × 4" lag PVC overlaps the metal shelf. may need to cut the final brick for the
screws and washers. Allow 1⁄16" for an course. Or, choose a pattern such as
expansion joint between shelf sections. running bond that uses cut bricks.
Remove the temporary support nails.
9 1
⁄ 2 to 1" gap
10 11
between
flashing and
veneer
Max. 3⁄ 8"
overhang
on shelf
Build up the corners two courses Attach another course of PVC flashing Use the story pole to mark layout
above ground level, and then attach to the wall so it covers the top course of lines for the tops of every fifth course of
line blocks and mason’s string to the bricks, and then staple building paper to bricks. Attach corrugated metal wall ties
end bricks. Fill in the field bricks so they the wall so it overlaps the top edge of the to the sheathing where the brick lines
align with the strings. Every 30 minutes, PVC flashing by at least 12". Mark wall- meet the marked wall-stud locations.
smooth mortar joints that are firm. stud locations on the building paper.162 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
12 13
Fill in the next course of bricks, applying mortar directly Add courses of bricks, building up corners first, and then onto the PVC flashing. At every third mortar joint in this course, filling in the field. Embed the wall ties into the mortar beds as tack a 10” piece of 3⁄8”-dia. cotton rope to the sheathing so it you reach them. Use corner blocks and a mason’s string to extends all the way through the bottom of the joint, creating verify the alignment, and check frequently with a 4-ft. level to a weep hole for drainage. Embed the metal wall ties in the make sure the veneer is plumb. mortar beds applied to this course.
14 15 Sill-nosing trim
Apply a 1⁄2”-thick mortar bed to the top course and begin Finish-nail the sill extensions to the windowsills. Nail sill- laying the rowlock bricks with the cut ends against the wall. nosing trim to the siding to cover any gaps above the rowlock Apply a layer of mortar to the bottom of each rowlock brick, course. Fill cores of exposed rowlock blocks with mortar and and then press the brick up against the sheathing with the top caulk any gaps around the veneer with silicone caulk. edge following the slope of the windowsills.
Brick & Block ■ 163
Mortared Brick Patio Tools & Materials ▸
Stiff brush or broom Isolation board
Circular saw 3
⁄8 or 1⁄2" plywood
S etting brick or concrete pavers into mortar is one
of the most beautiful—and permanent—ways to
dress up an old concrete slab patio. Mortared pavers
Mason’s trowel
Mortar mixing tools
Type S mortar
Burlap
arguably offer the most classic, finished appearance 4-ft. level Plastic sheeting
for either a backyard patio or a front entry stoop. The Rubber mallet Notched board
paving style used most often for mortared pavers is Mortar bag Mason’s string
the standard running-bond pattern, which is also the Jointing tool Straight 2 × 4
easiest pattern to install. Pointing trowel Eye and ear
Mortared pavers are appropriate for old concrete Concrete cleaner protection
slabs that are flat, structurally sound, and relatively free Pavers Work gloves
of cracks. Minor surface flaws are generally acceptable, Spray bottle
since the new mortar bed will compensate for slight
imperfections. However, existing slabs with significant
cracks or any evidence of shifting or other structural thinner versions (11⁄2 inches) and concrete pavers
problems will most likely pass on those same flaws to in various shapes and sizes. Any type you choose
the paver finish. For these, a nonmortared application is should be square-edged, to simplify the application
a safer solution. When in doubt, have your slab assessed and finishing of the mortar joints. When shopping for
by a qualified mason or concrete contractor to learn pavers, discuss your project with an expert masonry
about your options. New concrete slabs are also suitable supplier. Areas that experience harsh winters call for
for mortared paving, but make sure the concrete has the hardiest pavers available, graded SW or SX for
cured completely before applying the paver veneer. severe weather. Also make sure the mortar you use
Pavers for mortaring include natural clay brick is compatible with the pavers to minimize the risk of
units in both standard thickness (23⁄8 inches) and cracking and other problems.
Nothing dresses up an old concrete patio like brick or concrete pavers set in a bed of mortar. The mortaring process takes more
time and effort than many finishing techniques, but the look is timeless and the surface is extremely durable.164 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Set Pavers in a Mortar Bed 1 2
Prepare the patio surface for mortar by thoroughly cleaning Dry-lay the border pavers along the edge of the patio slab. the concrete with a commercial concrete cleaner and/ Gap the pavers to simulate the mortar joints using spacers cut or a pressure washer. Make sure the surface is completely from plywood equal to the joint thickness (3⁄8 or 1⁄2” is typical). free of dirt, grease, oil, and waxy residue. Note: Follow Adjust the pavers as needed to create a pleasing layout with manufacturer’s instructions for proper use and safety. the fewest cuts possible. Install isolation board along the foundation wall if the paving abuts the house; this prevents the mortar from bonding with the foundation.
3 4
Cut Paver
Isolation
BoardMist the concrete with water to Begin laying the border pavers by spreading a 1⁄2”-thick layer of mortar for three prevent premature drying of the mortar or four pavers along one edge of the patio using a mason’s trowel. Lay the first few bed and then mix a batch of mortar as pavers, buttering the leading edge of each with enough mortar to create the desired directed by the manufacturer. joint thickness. Press or tap each paver in place to slightly compress the mortar bed.
Brick & Block ■ 165
5
Remove excess mortar from the tops and sides of the Variation: To cover the edges of a raised slab, build wood
pavers. Use a level to make sure the pavers are even across forms similar to concrete forms (see pages 40 to 41). Set a gap
the tops and check the mortar joints for uniform thickness. between the forms and slab equal to the paver thickness plus
Tool the joints with a jointer as you go. Repeat the process to 1
⁄2". Install the edge pavers vertically or horizontally, as desired.
lay the remaining border pavers. Allow to dry as directed by
the manufacturer.
6 7
Spacer
Notched
screed
Spread and then screed mortar for the field pavers. Trowel Begin laying the field pavers (without buttering them).
on a 1⁄2"-thick layer of mortar inside the border, covering only Use the plywood spacers to set the gaps for mortar joints.
about 3 or 4 sq. ft. to allow for working time before the mortar Cut end pavers as needed. Keep the courses straight by
sets. Screed the mortar to a uniform 1⁄2" thickness using a setting the pavers along a string line referenced from the
notched board set atop the border pavers (set the interior end border pavers.
on a lumber spacer, as needed).166 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
8 9
As you work, check the heights of the pavers with a level or a Fill the paver joints with fresh mortar using a mortar bag to straight 2 × 4 to make sure all units are level with one another. keep the paver faces clean. Within each working section, fill If a paver is too high, press it down or tap it with a rubber the long joints between courses first, and then do the short mallet; if too low, lift it out, butter it’s bottom with mortar, joints between the paver ends. Overfill the joints slightly. and reset it. Repeat steps 6 through 8 to complete the paver installation, and then let the mortar bed dry.
10 11
Tool the joints with a jointing tool—again, complete the Let the mortar joints dry for a few hours (or as directed by long joints first, and then fill the next section. As the mortar the manufacturer) and then scrub the paver faces with a wet begins to set (turns from glossy wet to flat gray) in each tooled burlap rag to remove any excess mortar and residue. Cover section, scrape off excess mortar with a pointing trowel, being the surface with plastic for 48 hours. Remove the plastic, and careful not to smear mortar onto the paver faces. let the surface cure undisturbed for one week before using the patio.
Brick & Block ■ 167Natural Stone S tone is a natural landscaping material that is at home in any yard or garden. Elegant and graceful, natural stone weathers well and in many cases actually improves in appearance after it is installed. From tumbled textures with old-world appeal to slick, polished surfaces, stone can blend in quietly or make a bold design statement.
In this chapter: • Natural Stone Basics • Dry Stone Wall • Mortared Stone Wall • Stone Retaining Wall • Arroyo (Dry Stream Bed) • Stone Firepit • Mortared Flagstone Patio • Flagstone Garden Steps • Rock Garden • Stone Moon Window • Cobblestone Paver Patio • Sandset Flagstone Patio • Pebbled Stepping Stone Path • Zen Garden
■ 169
Natural Stone Basics
T he greatest challenges to working with natural
stone are dealing with its weight and its lack of
uniformity when it comes to size and shape. These
undesirable bumps, reshaping a stone to improve its
stability within the structure, and cutting stones to fit.
Once the stones are cut and ready to put into
challenges can be overcome with plenty of helpers, position, working with them is much like working with
creativity, and determination. If you’ve never worked any other placed masonry item.
with natural stone, take home a few pieces and
experiment before undertaking a large project.
Depending on the stone you choose, individual
pieces may be quite heavy. The best time to recruit How Much Do You Need? ▸
helpers and devise ramps and other lifting and
towing devices is before you come across a stone Before you visit a stoneyard, determine how much
that’s too heavy to move into place. Stone supply area you plan to cover—literally. Know the dimensions
yards frequently have specialty tools that you can of your project: height, width, length. Convert this into
rent or borrow. Those that don’t offer that service square footage. For a wall, you will multiply the length
undoubtedly will know local sources for such tools. and height to arrive at a measurement. This number
The unique nature of each piece makes it necessary will help a professional calculate how much stone you
to cut and sometimes shape or “dress” stones (pages should buy.
179). This often involves removing jagged edges and
Tucked into the crevices of this fieldstone sitting area are rock-loving plants like moss and creeping thyme that add color and
interest to the space.170 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Working with Stone A trip to a local stoneyard can be an inspiring start can be spread as surface material or used as a buffer to any stonescaping project. While you’re checking in drainages zones, such as against a home. Gravel out the inventory, take notes, snap pictures if you ranges in diameter from a quarter-inch to two inches. must, and ask lots of questions of professionals. Keep If gravel is river rock, its surface will be smooth, in mind, when you source stone from outside your rounded, shiny, and variegated in color. region, you will pay more for shipping and delivery. In Sand: You’ll generally find two types of sand: most cases buying native rocks from local stoneyards is coarse building sand and fine sand for landscaping or the way to go. sandboxes. Extremely fine sand used for sandblasting Aside from large stone pieces, gravel, sand, and has no use in stonescaping or landscaping. black dirt are essential building materials. You can obtain Black dirt: This material is usually sold in these materials in poly bags at garden or building centers. pulverized or sterilized forms. This is fine for For larger amounts, visit a landscape supply outlet and backfilling, but if you are planting, you’ll want to purchase them by the cubic yard or by the ton. amend the soil. Dirt is normally sold by the cubic Gravel: This material is essentially a chip off yard since the weight varies dramatically based on the rock—mechanically broken-down stone that the moisture content.
Hauling Materials ▸
You can save delivery charges (usually $35 to $50) and control delivery
times by hauling landscape materials yourself in a pickup or trailer. The
yard workers at the supply center will load your vehicle free of charge
with a front-end loader or skid loader. Do not overload your vehicle.
Although most operators are aware of load limits, they will typically
put in as much as you tell them to. As a general rule, a compact truck
(roughly the size of a Ford Ranger) can handle one scoop of dirt, sand,
or gravel, which is about three quarters of a cubic yard; a half-ton truck
(Ford F-150) will take a scoop and a half (a little over a cubic yard), and
a three-quarter ton truck (Ford-250) can haul two scoops (one and a
half cubic yards) safely. Be sure to check the gross vehicle weight and
payload data label on the driver’s door.
Loose materials used in stonescaping
include: smooth river rock for top dressing
A B C D (A); crushed rock for stable surface dressing
(B); crushed quartz for decorative top
dressing (C); trap rock for well-drained
sub-bases or decorative top dressing (not
E F G a good choice for walking surfaces) (D);
crushed limestone for sub-bases and top
dressing (E); small-diameter river rock for
top dressing and drainage (F); pea gravel
for top dressing (G); compactable gravelH I J K (class V or class II) for compacted sub-bases (H); coarse sand for paver beds (I); fine sand for gap-filling (J); black dirt for backfilling (K).
Natural Stone ■ 171
■ Tools & Materials
Even though planet Earth naturally provides a wealth If you’re doing the work yourself, don’t expect to find
of rocks and dirt in various levels of solidity, natural six tons of premium ashlar at your local building center
stone can get fantastically expensive. So it pays or gardening outlet. You’ll need to do your shopping at a
to use a sharp pencil when you’re estimating and specialty landscape supplier. Where possible (and if you
sharp tools when you’re working the stone to keep have access to an appropriate vehicle), select and haul
expensive waste to a minimum. the rock yourself to control quality and save delivery fees.
L
A
M
K
B E
F D
C
N
P O
G
H T
I
Q R
S
J
These tools are valuable helpers when working with natural stone. Mortar hawk (A); joining tool (B); pointing trowel (C); mason’s
trowel (D); circular saw with masonry blade (E); pick axe (F); masonry hoe (G); wrecking bar for prying small to medium stones (H);
square-end spade (I); heavy-duty spud bar for prying larger stones (J); mortar box (K); mortar bag (L); masonry saw (M); hand maul
(N); brick hammer (O); stone chisels (P); bricksets (Q); torpedo level (R); wire brush (S); mason’s string (T).
From left to right: a Mattock is
similar to a pick axe and is used for
digging or breaking up hard ground.
Also called a grub hoe. A 3-lb. hand
maul can be used to crush stone,
dress ragged stone edges, or drive
bricksets and chisels. Levels are used
to establish layouts and check stacked
stone or masonry units. Among the
more useful levels are a 4-ft. level for
measuring slopes and grade, a torpedo
level for checking individual units, and
a line level for setting layout strings.172 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
B
A CFrom left to right: a wheelbarrow (A) with at least 5-cu.-ft. capacity is a necessity for transporting stones, loose fill, and other supplies; a corded circular saw with a masonry blade (B), preferably diamond-tipped, is used to score and cut stones and masonry units; landscape paint (C) is used to outline projects. The paint can be delivered with the can held upside down and it degrades harmlessly.
A B
C
DFrom left to right: stone chisels and bricksets (A) are struck with a maul to fracture or dress stones and masonry units; prybars and wrecking bars (B) are used to reposition larger stones; loppers and pruning shears (C) are used to trim back overgrown plants; an axe (D) can be used to cut through roots in an excavation area or to cut down small tress or shrubs.
Tool Tip: Safety Gear ▸
Cutting and hauling stone calls for special safety
equipment, including:
• Protective knee pads • Sturdy gloves
• Steel-toe work boots • Eye and ear
• Hard hat protection
• Particle mask
Natural Stone ■ 173
■ Types & Forms of Stone
When choosing stone, you’ll need to decide what type fieldstone, marble, ashlar, veneer, and cobblestone.
and what form to use. If you’re shopping at a stone Some stone is uncut because its natural shape lends
supply yard, you’ll also find a wide range of shades itself to certain types of construction. Stone is cut thin
and textures. for use as facing (veneer) and wall caps (capstone).
The most common types of stone for outdoor Often, the project dictates the form of stone to use.
construction are shown below. In addition to a distinctive For example, most arches require stone with smooth,
look, each type has a specific durability and workability roughly square sides, such as ashlar, that can be laid
to consider. If you expect to do a lot of splitting, ask your up with very thin mortar joints.
local stone supplier to help you select stone that splits Once you’ve determined the type and form of
easily. If you’re laying a walk, select stone that holds up stone for your project, you can browse the wide range
well under foot traffic. Cost, of course, is also a factor. of shades and textures available and decide what best
Other things being equal, you will find that stone native complements the look and feel of your yard.
to your area is the most affordable. Note: You may find that in your area different terms
A stone’s form can be thought of as its shape are used for various types of stone. Ask your supply yard
or cut. Common forms (right) include flagstone, staff to help you.
Limestone is a heavy stone, moderately
easy to cut, medium to high strength,
used in garden walls, rock gardens, walks,
steps, and patios. Major U.S. sources:
Indiana, Wisconsin, Kansas, and Texas.
Granite is a dense, heavy stone, difficult
to cut, used for paving walks and building
steps and walls; the most widely used
building stone. Major U.S. sources:
Massachusetts, Georgia, Minnesota, North
Carolina, South Dakota, and Vermont.
Sandstone is a relatively lightweight
stone available in “soft” and “dense”
varieties and a wide range of colors.
Soft sandstone is easier to cut but also
lower in strength; used in garden walls,
especially in frost-free climates. Major U.S.
sources: New York, Arizona, Ohio,
and Pennsylvania.
Slate is a fine, medium-weight stone
that is soft and easy to cut but low in
strength; too brittle for wall construction
but a popular choice for walks, steps, and
patios; colors vary widely from region to
region. Major U.S. sources: Pennsylvania,
Virginia, Vermont, Maine, New York,
and Georgia.174 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Flagstone is large slabs of quarried stone cut
into pieces up to 3" thick; it is used in walks,
steps, and patios. Pieces smaller than
16" sq. are often called steppers.
Fieldstone is gathered
from fields, dry river
beds, and hillsides; it is
used in wall construction.
When split into smaller,
more manageable shapes,
fieldstone is often used in mortared construction.
Called river rock by some quarries because of the
river-bed origin of some fieldstone.
Ashlar is quarried stone smooth-cut into large blocks ideal for
creating clean lines with thin mortar joints.Rubble is irregular pieces of quarried stone, usually with one split or finished Veneer stone pieces are of natural or face; widely used in wall construction. manufactured stone, cut or molded for use in non-load-bearing, cosmetic applications such as facing exterior walls or freestanding concrete block walls.
Cobblestone is small cuts of quarried stone or fieldstone; it is used in walks and paths. Natural Stone ■ 175
■ Cutting Stone
Designate an area for cutting and shaping, preferably
a grassy spot that will absorb the shock of heavy
tools striking stone. This is your “cutting zone.” It is
important to keep children out of the dangerous area
where stone chips could fly. You may use sandbags
to anchor rounded stones while cutting. Or, you can
build a banker to absorb shock (see below). A banker
resembles a small sandbox, and you construct it with
two layers of stacked 2 × 2s, forming a frame. Sandwich
a piece of 3⁄4-inch-thick plywood between the two layers.
Pour sand on top of the plywood. You can set stone in
the sand while cutting and shaping. If you prefer to
stand while cutting, build up your banker by laying a
foundation of stacked concrete block.
Now that your cutting surface is in order, collect
all necessary tools and materials. The type of stone
will dictate this. Always wear protective goggles and
gloves while cutting, and if you are creating dust, wear
a nuisance-rated particle mask (using wet-cutting
techniques is a good way to limit the dust.)
Cutting stone calls for heavy-duty tools: a pitching
chisel for long clean cuts; a pointing chisel for
removing small bumps; a basic stone chisel; a sturdy Breaking stone is a simple process, but it requires a lot of
maul; a sledgehammer; and a mason’s hammer, which practice to be done well. A stone chisel, a maul, and a soft
has a pick at one end that is helpful for breaking surface are the primary tools you’ll need.
off small chips. For a circular saw, use a masonry
blade (preferrably diamond-tipped) designed for the
material you are cutting. Hard material like marble
and concrete will require a different blade than softer
Lifting and Moving Stone ▸
stones like flagstone and limestone. Along with the
Many of the projects in this book require large, heavy
hardware, you’ll need a pipe or 2 × 4 for cutting
stones. Even small stones can cause injury to your
flagstone. Also, keep on hand chalk or a crayon for
back if you don’t lift and move them properly. Always
marking cut lines.
support your back with lifting belts. Always bend at
your knees when you lift stone. If you can’t straighten
up, the stone is too heavy to lift by yourself.
Other helpful stone-moving tools are ramps and
simple towing devices, such as chains. When stacking
interlocking block to construct a retaining wall, you
may need a “helper” to lift stones as you build up
some height. You can use 2 × 4s as ramps, placing
a couple of them side-by-side to accommodate
larger blocks. Using stone as a support underneath a
ramp (2 × 4s), angle the ramp from the ground to the
retaining wall. From a squatting position, push the
stone up the ramp using your knees, not your back.
You can also use a come-along tool to drag heavy
A banker is a sand-filled wood box that provides a shock- stones. Gloves are a good idea, too.
absorbent surface for cutting stone.176 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Tips for Cutting Stone ▸
Laying stones works best when the sides (including the “Dress” a stone using a pointing chisel and maul to
top and bottom) are roughly square. If a side is sharply remove jagged edges or undesirable bumps. Position the
skewed, score and split it with a pitching chisel, and chisel at a 30 to 45º angle at the base of the piece to be
chip off smaller peaks with a pointing chisel or mason’s removed. Tap lightly all around the break line, and then
hammer. Remember: A stone should sit flat on its bottom more forcefully, to chip off the piece. Position the chisel
or top side without much rocking. carefully before each blow with the maul.■ Choosing Your Chisel Pointing chisel Pitching chisel Stone chisel
A pointing chisel is used to clean up A pitching chisel has a relatively wide A basic stone chisel can handle a edges and surfaces by knocking off blade for making long, clean cuts. variety of stonecutting tasks, including small chunks and ridges. cleaving stones in two.
Natural Stone ■ 177
Cutting Stone with a Circular Saw ▸
A circular saw lets you precut stones with broad
surfaces with greater control and accuracy than
most people can achieve with a chisel. It’s a
noisy tool, so wear ear plugs, along with a dust
mask and safety goggles. Install a toothless
masonry blade on your saw and start out with
the blade set to cut 1⁄8" deep. Make sure the
blade is designed for the material you’re cutting.
Some masonry blades are designed for hard
materials like concrete, marble, and granite.
Others are for soft materials, like concrete
block, brick, flagstone, and limestone. Wet the
stone before cutting to help control dust, and
then make three passes, setting the blade 1⁄8"
deeper with each pass. Repeat the process on
the other side. A thin piece of wood under the
saw protects the saw foot from rough masonry
surfaces. Remember: Always use a GFCI outlet or
extension cord when using power tools outdoors.
■ How to Cut Fieldstone
1 2
Place the stone on a banker or prop it with sandbags and Score along the line using moderate blows with a chisel
mark with chalk or a crayon all the way around the stone, and maul, and then strike solidly along the score line with
indicating where you want it to split. If possible, use the natural a pitching chisel to split the stone. Dress the stone with a
fissures in the stone as cutting lines. pointing chisel.178 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Cut Flagstone 1 2
Trying to split a large flagstone in half can lead to many Score along the line on the back side of the stone (the side that unpredicted breaks. For best results, chip off small sections at won’t be exposed) by moving a chisel along the line and striking a time. Mark the stone on both sides with chalk or a crayon, it with moderate blows with a maul. Option: If you have a lot of indicating where you want it to split. If there is a fissure nearby, cutting to do, reduce hammering fatigue by using a circular saw mark your line there since that is probably where the stone will to score the stones and a maul and chisel to split them. Keep the break naturally. stone wet during cutting with a circular saw to reduce dust.
3
Turn the stone over, place a pipe or 2 × 4 directly under the Option: If a paving stone looks too big compared to other chalk line, and then strike forcefully with the maul on the end stones in your path, simply set the stone in place and strike of the portion to be removed. a heavy blow to the center with a sledge hammer. It should break into several usable pieces.
Natural Stone ■ 179
■ Laying Stone
The methods of laying stone are as varied as the stone
masons who practice the craft. But all of them would
agree on a few general principles:
• Thinner joints are stronger joints. Whether you
are using mortar or dry-laying stone, the more
contact between stones, the more resistance to
any one stone dislodging.
• Tie stones are essential in vertical structures, such
as walls or pillars. These long stones span at least
two-thirds of the width of the structure, tying
together the shorter stones around them.
• When working with mortar, most stone masons
point their joints deep for aesthetic reasons.
The less mortar is visible, the more the stone
itself is emphasized.
• Long vertical joints, or head joints, are weak spots
in a wall. Close the vertical joints by overlapping
them with stones in the next course, similar to a
running-bond pattern in a brick or block wall.
Thin joints are the strongest. When working with mortar,
• The sides of a stone wall should have an inward
joints should be 1⁄2 to 1" thick. Mortar is not intended to
slope (called batter) for maximum strength. create gaps between stones but to fill the inevitable gaps and
This is especially important with dry-laid stone. strengthen the bonds between stones. Wiggle a stone once it
Mortared walls need less batter. is in place to get it as close as possible to adjoining stones.
Blend large and small stones in walks or in vertical Place uneven stone surfaces down and dig out the soil
structures to achieve the most natural appearance. In addition underneath until the stone lies flat. Use the same approach in
to enhancing visual appeal, long stones in a walk act like the tie the bottom course of a dry-laid wall, only make sure stones
stones in a wall, adding strength by bonding with other stones. at the base of a wall slope toward the center of the trench.180 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Tips for Laying Stone Walls ▸
Tie Stone Shiner
Tie Stone
Tie stones are long stones that span most of the width A shiner is the opposite of a tie stone—a flat stone on the
of a wall, tying together the shorter stones and increasing side of a wall that contributes little in terms of strength. A
the wall’s strength. As a guide, figure that 20% of the shiner may be necessary when no other stone will fit in
stones in a structure should be tie stones. a space. Use shiners as seldom as possible, and use tie
stones nearby to compensate.Lay stones in horizontal courses, With irregular stone, such as Use a batter gauge and level to lay up where possible (a technique called untrimmed rubble or fieldstone, building dry stone structures so the sides angle ashlar construction). If necessary, stack course by course is difficult. Instead, inward. Angle the sides of a wall 1” for two to three thin stones to match the place stones as needed to fill gaps and every 2 ft. of height—less for ashlar and thickness of adjoining stones. to overlap the vertical joints. freestanding walls, twice as much for round stone and retaining walls.
Natural Stone ■ 181
Dry Stone Wall
S tone walls are beautiful, long-lasting structures
that are surprisingly easy to build provided you
plan carefully. A low stone wall can be constructed
sorted by size and shape. You’ll probably also need to
shape some of the stones to achieve consistent spacing
and a general appearance that appeals to you.
without mortar using a centuries-old method known To shape a stone, score it using a circular saw
as dry laying. With this technique, the wall is actually outfitted with a masonry blade. Place a mason’s chisel on
formed by two separate stacks that lean together the score line and strike with a maul until the stone breaks.
slightly. The position and weight of the two stacks Wear safety glasses when using stonecutting tools.
support each other, forming a single, sturdy wall. A
dry stone wall can be built to any length, but its width
must be at least half of its height. Tools & Materials ▸
You can purchase stone for this project from a quarry
or stone supplier, where different sizes, shapes, and Mason’s string and Mortar mix
colors of stone are sold, priced by the ton. The quarry or stakes Trowel
stone center can also sell you Type M mortar—necessary Compactable gravel Stiff-bristle brush
for bonding the capstones to the top of the wall. Ashlar stone Work gloves
Building dry stone walls requires patience and Capstones
a fair amount of physical effort. The stones must be
It is easiest to build a dry stone wall with ashlar—stone that has been split into roughly rectangular blocks. Ashlar stone is
stacked in the same running-bond pattern used in brick wall construction; each stone overlaps a joint in the previous course. This
technique avoids long vertical joints, resulting in a wall that is attractive and also strong.182 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build a Dry Stone Wall 1 2 3
Lay out the wall site using stakes and Select appropriate stones and lay the Lay the next course, staggering the mason’s string. Dig a 6”-deep trench first course. Place pairs of stones side by joints. Use pairs of stones of varying that extends 6” beyond the wall on all side, flush with the edges of the trench lengths to offset the center joint. sides. Add a 4” crushed stone sub-base and sloping toward the center. Use stones Alternate stone length, and keep the to the trench, creating a”V” shape by of similar height; position uneven sides height even, stacking pairs of thin stones sloping the sub-base so the center is face down. Fill any gaps between the if necessary to maintain consistent about 2” deeper than the edges. shaping stones with small filler stones. height. Place filler stones in the gaps.
4 5
Tie stonesEvery other course, place a tie stone every 3 ft. You Mortar the capstones to the top of the wall, keeping the may need to split the tie stones to length. Check the wall mortar at least 6” from the edges so it’s not visible. Push the periodically for level. capstones together and mortar the cracks in between. Brush off dried excess mortar with a stiff-bristle brush.
Natural Stone ■ 183
Mortared Stone Wall
T he mortared stone wall is a classic that brings
structure and appeal to any yard or garden. Square-
hewn ashlar and bluestone are the easiest to build
Laying a mortared stone wall is labor-intensive but
satisfying work. Make sure to work safely and enlist
friends to help with the heavy lifting.
with, though fieldstone and rubble also work well and
make attractive walls.
Because the mortar turns the wall into a Tools & Materials ▸
monolithic structure that can crack and heave with a
freeze-thaw cycle, a concrete footing is required for a Tape measure Concrete materials
mortared stone wall. To maintain strength in the wall, Pencil for foundation
use the heaviest, thickest stones for the base of the Chalk line Ashlar stone
wall and thinner, flatter stones for the cap. Small whisk broom Type N or Type S
As you plan the wall layout, install tie stones— Tools for mixing mortar mortar
stones that span the width of the wall (page Maul Stakes and
183)—about every three feet, staggered through the Stone chisel mason’s line
courses both vertically and horizontally throughout Pitching chisel Scrap wood
the wall. Use the squarest, flattest stones to build the Trowel Muriatic acid
“leads,” or ends of the wall first, and then fill the middle Jointing tool Bucket of water
courses. Plan for joints around one inch thick and make Line level Sponge
sure joints in successive courses do not line up. Follow Sponge Eye protection and
this rule of thumb: Cover joints below with a full stone Garden hose work gloves
above; locate joints above over a full stone below.
A mortared stone wall made from ashlar adds structure and classic appeal to your home landscape. Plan carefully and enlist
help to ease the building process.184 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build a Mortared Stone Wall 1 2
Pour a footing for the wall and allow it to cure for one week Dry-lay the entire first course. Starting with a tie stone at (pages 46 to 49). Measure and mark the wall location so it is each end, arrange stones in two rows along the chalk lines centered on the footing. Snap chalk lines along the length of with joints about 1” thick. Use smaller stones to fill the center the footing for both the front and the back faces of the wall. of the wall. Use larger, heavier stones in the base and lower Lay out corners using the 3-4-5 right angle method. courses. Place additional tie stones approximately every 3 ft. Trim stones as needed.
3 4
Mix a stiff batch of Type N or Type S mortar, following the Firmly press the first tie stone into the mortar so it is manufacturer’s directions (pages 28 to 29). Starting at an end or aligned with the chalk lines and relatively level. Tap the top of corner, set aside some of the stone and brush off the foundation. the stone with the handle of the trowel to set it. Continue to Spread an even, 2” thick layer of mortar onto the foundation, lay stones along each chalk line, working to the opposite end about 1⁄2” from the chalk lines—the mortar will squeeze out of the wall. a little.
(continued)
Natural Stone ■ 185
5 6
After installing the entire first course, As you work, rake the joints using a Variation: You can also tool joints for
fill voids along the center of the wall scrap of wood to a depth of 1⁄2"; raking a cleaner, tighter mortared joint. Tool
that are larger than 2" with smaller joints highlights the stones rather than the joints when your thumb can leave an
rubble. Fill the remaining spaces and mortared joints. After raking, use a whisk imprint in the mortar without removing
joints with mortar, using the trowel. broom to even the mortar in the joints. any of it.
7 8
Drive stakes at the each end of the wall and align a If heavy stones push out too much mortar, use wood
mason’s line with the face of the wall. Use a line level to level wedges cut from scrap to hold the stone in place. Once the
the string at the height of the next course. Build up each end mortar sets up, remove the wedges and fill the voids with
of the wall, called the “leads,” making sure to stagger the joints fresh mortar.
between courses. Check the leads with a 4-ft. level on each
wall face to make sure it is plumb.186 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Removing Mortar ▸ 9
Have a bucket of water and a sponge handy Fill the middle courses between the leads by first dry
in case mortar oozes or spills onto the face of the laying stones for placement and then mortaring them in
stone. Wipe mortar away immediately before it place. Install tie stones about every 3 feet, both vertically and
can harden. horizontally, staggering their position in each course. Make
sure joints in successive courses do not fall in alignment.10 11
Install cap stones by pressing flat stones that span the width Allow the wall to cure for one week, and then clean it using of the wall into a mortar bed. Do not rake the joints, but clean a solution of 1 part muriatic acid and 10 parts water. Wet the off excess mortar with the trowel and clean excess mortar wall using a garden hose, apply the acid solution, and then from the surface of the stones using a damp sponge. immediately rinse with plenty of clean, clear water. Always wear goggles, long sleeves and pants, and heavy rubber gloves when using acids.
Natural Stone ■ 187
Stone Retaining Wall
R ough-cut wall stones may be dry stacked (without
mortar) into retaining walls, garden walls, and
other stonescape features. Dry-stack walls are able to
Drainage gravel can help keep the soil from turning to
mud, which will slump and press against the wall.
The same basic techniques used to stack natural
move and shift with the frost, and they also drain well stone in a retaining wall may be used for building a
so they don’t require deep footings and drainage tiles. short garden wall as well. Obviously, there is no need
Unlike fieldstone and boulder walls, short wall-stone for drainage allowances or wall returns in a garden
walls can be just a single stone thick. wall. Simply prepare a base similar to the one shown
In the project featured here, we use rough-split here and begin stacking. The wall will look best if it
limestone blocks about eight by four inches thick and in wanders and meanders a bit. Unless you’re building a
varying lengths. Walls like this may be built up to three very short wall (less than 18 inches), use two parallel
feet tall, but keep them shorter if you can, to be safe. courses that lean against one another for the basic
Building multiple short walls is often a more effective construction. Cap it with flat capstones that run the
way to manage a slope than to build one taller wall. full width of the wall (see page 192).
Called terracing, this practice requires some planning.
Ideally, the flat ground between pairs of walls will be
approximately the uniform size. Tools & Materials ▸
A dry-laid natural stone retaining wall is a very
organic-looking structure compared to interlocking Goggles, gloves, Torpedo level
block retaining walls (see page 134). One way to steel-toe boots Straight 2 × 4
exploit the natural look is to plant some of your Mattock with pick Hand tamper
favorite stone-garden perennials in the joints as you Hatchet or loppers Compactable gravel
build the wall(s). Usually one plant or a cluster of Spades Ashlar wall stone
three will add interest to a wall without suffocating it Measuring tape Drainage gravel
in vegetation or compromising its stability. Avoid plants Mason’s string Landscape fabric
that get very large or develop thick, woody roots or Line level Block-and-stone
stems that may compromise the stability of the wall. Stakes adhesive
A well-built retaining wall has a slight lean, called Hand maul Caulk gun
a batter, back into the slope. It has a solid base and Garden rake
the bottom course is dug in behind the lower terrace.
A natural stone retaining wall not only adds a stunning framework to your landscape, but it also lends a practical hand to
prevent hillsides and slopes from deteriorating over time.188 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Cross Sections: Stone Retaining Walls Wall blocks (ashlar)
Backfill Batter
Original slope
Landscape fabric
Setback
Drainage gravel
Compacted gravel
Original slope
Retaining Return
wall wall
Compacted baseA stone retaining wall breaks up a slope to neat flat lawn areas that are more usable (top). A series of walls and terraces (bottom) break up larger slopes. Short return walls (inset) create transitions to the yard.
Natural Stone ■ 189
■ How to How to Build a Stone Retaining Wall
1 2
Dig into the slope to create a trench for the first wall. Level the bottom of the trench and measure to make sure
Reserve the soil you remove nearby—you’ll want to backfill you’ve excavated deeply enough.
with it when the wall is done.
3 4
After compacting a base, cover the trench and hill slope Place the first course of stones in rough position. Run a
with landscape fabric, and then pour and level a 1" (3 cm) layer level mason’s string at the average height of the stones.
of coarse sand.190 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
5 6
Add or remove gravel under each stone to bring the front Begin the second course with a longer stone on each end edges level with the mason’s string. so the vertical gaps between stones are staggered over the first course.
7 8
Finish out the second course. Use shards and chips of Finish setting the return stones in the second course, stone as shims where needed to stabilize the stones. Check to making adjustments as needed for the return to be level. make sure the ½” (3 mm) setback is followed.
(continued)
Natural Stone ■ 191
9 10
Backfill behind the wall with river rock or another good Fold the landscape fabric over the drainage rock (the main
drainage rock. job of the fabric is to keep soil from migrating into the drainage
rock and out the wall) and backfill behind it with soil to level
the ground.
11 12
Trim the landscape fabric just behind the back of the wall, Finish the wall by capping it off with some of your nicer, long
near the top. flat stones. Bond them with block-and-stone adhesive.192 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
13
Level off the soil behind the wall with a garden rake. Add additional walls if you are terracing.
Planting Your Retaining Wall ▸
Natural stone retaining walls look
quite lovely in their own right.
However, you can enhance the effect
by making some well-chosen planting
choices for the wall itself. You can
plan for this in the wall construction
by leaving an extra wide gap between
two stones in one of the courses
and then planting in the gap. Or you
can replace a stone in the wall with
a shorter one, also creating a gap. To
plant a gap, cut the fabric and set a
good-size, bare-root perennial of an
appropriate species to the bottom of
this joint. Fan out the roots over the
soil and use sphagnum moss to plug
up the gaps in the wall around plants.
Adhere the stone in the next course
that bridges the gap with block-and-
stone adhesive. Keep plants well
watered until established. Eventually,
the plant roots will hold the soil Set plants in natural-looking clusters of the same species. Do not suffocate
instead of the moss. the wall with too many plants.
Natural Stone ■ 193
Arroyo (Dry Streambed)
A n arroyo is a dry streambed or watercourse in
an arid climate that directs water runoff on the
rare occasions when there is a downfall. In a home
landscape an arroyo may be used for purely decorative
purposes, with the placement of stones evoking water
where the real thing is scarce. Or it may serve a vital
water-management function, directing storm runoff
away from building foundations to areas where it may
percolate into the ground and irrigate plants, creating
a great spot for a rain garden. This water management
function is becoming more important as municipalities
struggle with an overload of storm sewer water, which
can degrade water quality in rivers and lakes. Some
communities now offer tax incentives to homeowners
who keep water out of the street.
When designing your dry streambed, keep it
natural and practical. Use local stone that’s arranged
as it would be found in a natural stream. Take a field
trip to an area containing natural streams and make
some observations. Note how quickly the water depth
drops at the outside of bends where only larger stones
can withstand the current. By the same token, note
how gradually the water level drops at the inside of
broad bends where water movement is slow. Place
smaller river-rock gravel here, as it would accumulate
in a natural stream.
Large heavy stones with flat tops may serve as
step stones, allowing paths to cross or even follow dry
stream beds.
The most important design standard with dry An arroyo is a drainage swale lined with rocks that direct
runoff water from a point of origin, such as a gutter downspout,
streambeds is to avoid regularity. Stones are never
to a destination, such as a sewer drain or a rain garden.
spaced evenly in nature and nor should they be in
your arroyo. If you dig a bed with consistent width, it
will look like a canal or a drainage ditch, not a stream.
And consider other yard elements and furnishings. For Important: Contact your local government before
example, an arroyo presents a nice opportunity to add deliberately routing water toward a storm sewer; this
a landscape bridge or two to your yard. may be illegal.
Tools & Materials ▸
Landscape paint Landscape fabric 6 to 18" dia. Native grasses or other
Carpenter’s level 6-mil black plastic (15 to 46 cm) perennials for banks
Spades Mulch river-rock boulders Eye protection and
Garden rake 8" (20 cm)-thick ¾ to 2" (19 to 51 mm) work gloves
Wheelbarrow steppers river rock194 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build an Arroyo 1 Rain garden. May be lined with stone for sparse plantings
Flat steppers need to be at
least 6" (15 cm) tall.
River rock gravel on
inside of bend where
water slows
Dry stream about
3 ft. (91 cm) wide Stream widens to
Gutter 5 ft (1.5 m) at curve
Big boulders or
angular ledgeCreate a plan for the arroyo. The best designs have a very natural shape and a rock distribution strategy that mimics the look of a stream. Arrange a series of flat steppers at some point to create a bridge.
2 3
Lay out the dry stream bed, following the native Excavate the soil to a depth of at least 12” (30 cm) in the topography of your yard as much as possible. Mark the borders arroyo area. Use the soil you dig up to embellish or repair and then step back and review it from several perspectives. your yard.
(continued)
Natural Stone ■ 195
4 5 6
Widen the arroyo in selected areas to Install an underlayment of Set larger boulders at outside
add interest. Rake and smooth out the landscape fabric over the entire dry bends in the arroyo. Imagine that there
soil in the project area. streambed. Keep the fabric loose so is a current to help you visualize where
you have room to manipulate it later the individual stones could naturally
if the need arises. end up.
7
Place flagstone steppers or boulders with relatively flat surfaces in a stepping-stone pattern to make a pathway across the
arroyo (left photo). Alternately, create a “bridge” in an area where you’re likely to be walking (right photo).196 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
8
Add more stones, including steppers and medium-size landscape boulders. Use smaller aggregate to create the stream bed, filling in, around, but not covering, the larger rocks.
What is a9 Rain Garden? ▸ A rain garden is simply a shallow, wide depression at least ten feet away from a basement foundation that collects storm water runoff. Rain gardens are planted with native flood-tolerant plants and typically hold water for only hours after rainfall. Check your local garden center or Extension Service to find details about creating rain gardens in your area.
Dress up your new arroyo by planting native grasses and perennials around its banks.
Natural Stone ■ 197
Stone Firepit
A firepit is a backyard focal point and gathering
spot. The one featured here is constructed around
a metal liner, which will keep the fire pit walls from
Tools & Materials ▸
overheating and cracking if cooled suddenly by rain Wheelbarrow Plate vibrator
or a bucket of water. The liner here is a section of Landscape paint Metal firepit liner
36-inch-diameter corrugated culvert pipe. Check local String and stakes Compactable gravel
codes for stipulations on pit area size. Many codes Spades Top-dressing rock
require a 20-foot-diameter pit area. Metal pipe (trap rock)
Ashlar wall stones add character to the fire pit Landscape edging Wall stones
walls, but you can use any type of stone, including Level Eye protection and
cast concrete retaining wall blocks. You’ll want to Garden rake work gloves
prep the base for the seating area as you dig the fire
pit to be sure both rest on the same level plane.
Some pointers to consider when using your fire pit include: 1) Make sure there are no bans or restrictions in effect; 2) Evaluate
wind conditions and avoid building a fire if winds are heavy and/or blowing toward your home; 3) Keep shovels, sand, water, and a
fire extinguisher nearby; 4) Extinguish fire with water and never leave the fire pit unattended.198 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Cross Section: Firepit Wall blocks Liner (ashlar or interlocking) (culvert pipe)
Nonflammable
ground cover
2"
2"
4"
Compacted gravel■ Plan View: Firepit Edging material contains top dressing and assists when mowing.
36"
Top-dressing
ground cover
(trap rock)
20 ft.
Natural Stone ■ 199
■ How to Build a Firepit
1 2 3
10 ft. (6 m)
radius
Outline the location for your firepit Remove a 4"-deep layer of sod and Dig a 4"-deep trench for the
and the firepit safety area by drawing dirt in the firepit and safety areas (the perimeter stones that will ring the
concentric circles with landscape paint depth of the excavation depends on pit liner.
using a string and pole for guidance. what materials you’re installing in the
safety zone.)
4 5
Fill the trench for the perimeter stones with compactable Place your metal fire ring so it is level on the gravel layer
gravel and tamp thoroughly. Then scatter gravel to within 2½" and centered around the center pipe.
of the paver edging top throughout the project area. It is not
necessary to tamp this layer at this time.200 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
6 7
Arrange the first course of wall blocks around the fire ring. Install the second course of retaining wall block, taking care Keep gaps even and check with a level, adding or removing to evenly stagger the vertical joints on the first and second gravel as needed. courses. Add the remaining courses.
8 9
Compact the compactable gravel in the seating/safety Place and compact a layer of top-dressing rock in the area using a rental plate vibrator. seating/safety area to complete the firepit.
Natural Stone ■ 201
Mortared Flagstone Patio
T he stately flagstone patio can be sandset or
mortared using lightly trimmed stone or naturally
irregular stone shapes. If you’re sandsetting, which is a
Tools & Materials ▸
good idea in colder climates, you’ll have the best luck Paint roller with Trowel
if you cut the stones so they are as large as possible extension pole Straight 2 × 4 stud
and have straight edges. Small stones don’t provide Pencil Grout bag
much bearing when they’re resting on the sand. But Small whisk broom Jointing tool
they can be a very effective part of the design if you Tools for mixing Sponge
embed them into mortar, as we do here. mortar Garden hose
You can install a mortared flagstone patio over Shovel Concrete bonding
an old concrete patio if it is reasonably good repair Maul agent
or you can pour a new concrete base that’s at least Stone chisel Flagstone stone
two inches thick with five inches of compacted rock Pitching chisel Type N or Type S
below for drainage. If you are sandsetting, you’ll want 4-ft. level mortar
a layer of coarse sand that’s at least one or two inches Rubber mallet Acrylic fortifier
thick over a well-compacted base of gravel (see the Eye protection and Stone sealer
sandset flagstone patio project starting on page 226 work gloves
for more information).
The flagstone patio is a classic element of modern landscape design. Bluestone (above) is one of the most popular types but
may not be available in all areas since specific types vary by region.202 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build a Mortared Flagstone Patio 1 2
Thoroughly clean the concrete slab. While the slab Once the bonding agent has set up per the manufacturer’s doesn’t need to be in perfect condition, it does need to be recommendations, dry lay stones on the patio to determine sound. Repair large cracks or holes. After repairs have cured, an appealing layout. Work from the center outward and evenly apply a latex bonding agent to the patio surface, following the distribute large stones and smaller ones, with 1⁄2 to 1” joints manufacturer’s instructions. between them.
3
Cut stones to size as needed. Mark the cutting line with Variation: For a more rustic appearance, allow stones to chalk, and then cut the stone, following the techniques on overhang the edges of the slab. Stones thicker in size can page 179. At the sides of the slab, cut stones even with the overhang as much as 6”, provided that the slab supports no edges to accommodate edging treatments. less than two-thirds of the stone. Thinner stones should not overhang more than 3”. After stones are mortared in place, fill in beneath the overhanging stones with soil.
(continued)
Natural Stone ■ 203
4 5
Mix a stiff batch of Type N or Type S mortar, following the Firmly press the first large stone into the mortar, in
manufacturer’s directions. Starting near the center of the patio, its same position as in the layout. Tap the stone with a
set aside some of the stone, maintaining their layout pattern. rubber mallet or the handle of the trowel to set it. Use a
Spread a 2" thick layer of mortar onto the slab. 4-ft. level and a scrap of 2 × 4 to check for level; make any
necessary adjustments.
6 7
Using the first stone as a reference for the course height, As you work, check for level often, using a straight
continue to lay stones in mortar, working from the center of length of 2 × 4 and the 4-ft. level. Tap stones to make minor
the slab to the edges. Maintain 1⁄2 to 1" joints. adjustments. Once you’re done, let the mortar set up for a
day or two before walking on it.204 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
8 9
Use a grout bag to fill the joints with mortar (add acrylic Once the mortar is stiff enough that your thumb leaves fortifier to the mix to make the mortar more elastic). Do not an impression without mortar sticking to it, rake the joints just overfill the joints. Pack loose gravel and small rocks into gaps enough so the mortar is even with the surface of the stone, so first to conserve mortar and make stronger joints. Wipe up water cannot pool. Use a whisk broom to shape the mortar. spilled mortar.
10
Allow the mortar to cure for a few days, and then clean the patio with clear water and a stiff bristle brush. After the mortar cures for a week, apply a stone sealer, following the manufacturer’s instructions.
Natural Stone ■ 205
Flagstone Garden Steps
F lagstone garden steps are an ideal solution for
managing low slopes. They consist of broad
flagstone treads and blocky ashlar risers, commonly
Tools & Materials ▸
sold as wall stone. The risers are prepared with Stakes Excavating tools
compactable gravel beds on which the flagstone treads Mason’s string Compactable gravel
rest. This project features flagstone and wall stone in Landscape marking Coarse sand
their originally split state (as opposed to sawn). paint 3-lb. maul
The process of fitting stones together involves a lot String level Hand tamper
of cutting and waste, so plan on purchasing 40 percent Straight 2 × 4 Wall stone
more stone material than your plans require. Choose Torpedo level Flagstones
stone with uniform thickness, if possible. Flagstone 4-ft. level Block-and-stone
steps work best when you create the broadest possible Measuring tape adhesive
treads. Think of them as a series of terraced patios. Spun-bonded Work gloves
landscape fabric
Flagstone garden steps typically have a casual appearance that follows the shape of your yard naturally. Broad steppers are
used for the treads with the front set on smaller steppers to level them and function as risers.206 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Cross Section: Garden Steps Flagstone treads
Riser stones
Riser stones
Return
stones
Return stones
Compactable gravel■ Stone Step Variations
Flagstone steps create a rustic pathway in a natural Concrete and natural stone create an elegant and uniform garden setting. They can be installed using the natural hill walkway for a gentle slope. slope as a riser.
Natural Stone ■ 207
■ How to Build Flagstone Steps
1 2
Thread a line level onto a mason’s string and tie the ends Excavate for the first step and the stone walls risers and
of the string to stakes at the top and bottom of the stair returns. Dig deep enough to accommodate 4" of compactable
installation site. With the string level, measure the difference in gravel and 1" of sand throughout. This means you’ll be
distance from the string to the ground at the top and bottom excavating a shallow area for the tread and a deeper U-shaped
of the steps to find the total run. See pages 58 to 59 for more trench for the wall stones.
help on designing steps.
3 4
Pour a layer of compactable gravel into the U-shaped Position the riser stones and the return stones in the trench
trench for the wall stones. Compact the gravel with a tamper and level them. Add or remove gravel as necessary and then
or post and then top it off with another layer that should not rap them gently on the tops with a hand maul to set them. Use
be compacted. a wood block to protect the stones from the maul.208 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
5 6
Line the area under the first tread with landscape fabric, Measure the step/run distance back from the face of the drawing it up to cover the insides of the risers and returns. first risers and set a mason’s line across the sand bed. Set Add a layer of compactable gravel and tamp down to within the second course of risers and returns as you did the first, 1” of risers and returns. Fill with sand and level with a 2 × 4. without digging risers on to the bottom (the bottom tread will Slope gravel slightly from back to front for drainage. reduce risers’ effective height).
7 8
Begin laying out flagstone treads. First, position them Fill in gaps between larger stones by trimming smaller like a puzzle to determine if cuts are necessary. Leave a pieces to fit. Fill smaller stones near the back. Don’t allow stones consistent distance between stones. Allow steps to hang to touch one another when in place and do not cut stones too about 2” over risers. small. Ideally, each should be at least the size of a dinner plate.
(continued)
Natural Stone ■ 209
9 10
Pack wet sand underneath low areas and remove sand Use thin pieces of broken stone as shims to raise wall
underneath high areas until all the flags on the tread are stones to their required level. Make sure shims are sturdy
basically flat and even. Use a level as a guide. enough that they won’t flake apart easily. Use block-and-stone
adhesive to hold the shims in place. Make sure there is no path
for sand to wash out from beneath the treads. Do not use sand
in place of shims to raise wall stones.
11 12
Continue adding steps and making your way up the slope. Fill the joints between stones with coarse sand to bind
You shouldn’t need to trench for risers, but you may need to them together and for a more finished appearance. Granite
move some dirt so you can pack it in and install the return sand works well for this purpose, or choose polymeric sand
stones. The bottom of the risers should be at the same height that resists wash-out better than regular builder’s sand. Inspect
as the bottoms of the tread on the step below. The top step steps regularly for the first few weeks and make adjustments
often will not require returns. to height of stones as needed.210 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Natural Stone Step Design ▸ Steps made using natural stones most frequently are makes sense from both a practical and an aesthetic point found in locations where the setting is fairly wild, or at of view, to design the steps as a series of landings. Here, least very casual. Whenever you design and build steps, uniform landing depth is desirable, but it is not required you should be aware of safety issues, but the fact is that and you may want to vary it a little bit so your step in a rustic setting away from permanent structures you accommodates a slope more naturally. have a little more latitude when it comes to design. This A series of large, flat stones can make very striking works out quite well with natural stone steps, because in steps, with each flat stone making up a single tread. In such many cases the natural sizes and shapes of the stones will situations you’ll need to do more grading and modification inform the dimensions of the steps. of the slope terrain to fit the dimensions of the stones. A stairway built using natural or cast cobbles, such as In either of the cases above, adding a handrail is the left photo below, can be manipulated pretty easily to probably not required by codes. But it is always a good manage the rise in a fairly uniform way. However, it often idea and it will be much appreciated by your visitors.
Natural Stone ■ 211
Rock Garden
R ock gardens offer a good way to landscape
difficult sites. Sloped areas or sites with sandy
soil, for instance, are unfavorable for traditional
and positioning large rocks is the most difficult task.
If your rock garden site is large, consider hiring a
landscape contractor to deliver and place the rocks
lawns but are ideal for rock gardens. A rock for you.
garden is also a good choice if you’re looking for Rock gardens will look more natural if they’re
an alternative to traditional ground covers and built with stones that are all the same variety—or
garden beds. Rock gardens traditionally feature at least with stones that are similar in appearance.
hardy, alpine plant varieties that typically require Using stone like that found in natural outcroppings
infrequent watering. in your area is a good idea. On the other hand,
Building a rock garden requires excavating the site gardens with a larger variety of stone types have more
(preferably a sloping or terraced area) and preparing visual variety and high potential for a very dramatic
the soil, placing the rocks, and planting. Moving appearance when arranged with some skill.
Common Rock Garden Plants ▸ Tools & Materials ▸
Hens-and-Chicks Rock jasmine Wheelbarrow Course sand
Snow-in-Summer Rockcress Shovel Pea gravel or rock
Coral bells Dwarf juniper Work gloves chips
Sedum Yarrow Eye protection Moss
Dianthus Mulch Buttermilk or yogurt
Eye protection and Putty knife
work gloves Alpine plants
A rock garden is an accessible first natural stone project. Rock gardens make a statement in a landscape and they are an
attractive alternative to traditional garden beds.212 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build a Rock Garden 1 2
The best site for a rock garden is sloping or terraced, ideally Begin at the base of the site, placing the most substantial with southeast exposure. It should be completely free of deep- stones first. The idea is to create the impression of a natural rooted weeds. If no such space is available, build up a raised subterranean rock formation weathered from exposure. Set the bed with southeast exposure. The alpine plants traditionally stones in the soil so they are at least half buried and so their used in rock gardens require soil with no clay and with excellent most weathered surfaces are exposed. Slightly less than half drainage. If the existing soil has clay, remove any ground cover of the surface of the site should be rock. Avoid even spacing or and excavate the site to a depth of around 18”. Replace the soil rows of rocks. Once the rocks are in place, cover the soil with a with equal parts loam, peat moss, and coarse sand. mulch of complementary pea gravel or rock chips.
3 4
“New” rocks moved to the site will need to weather before After the rocks are in place for a few days and the soil has they will look natural. Encourage weathering by promoting settled, begin planting the garden. As with the rocks, focus on moss and lichen growth. In a blender, combine a handful of native plant varieties and strive for natural placement, without moss with a cup of buttermilk or yogurt. Distribute the mixture excessive variety. You can plant several sizes, from small trees on the exposed faces of rocks with a putty knife to promote or shrubs to delicate alpine flowers. Place plants in crevices moss growth. and niches between rocks, allowing them to cascade over the surface of the rock.
Natural Stone ■ 213
Stone Moon Window
Y ou can build circular openings into brick or
stone walls using a single semicircular wood
form. Moon windows can be built to any dimension,
Tools & Materials ▸
although lifting and placing stones is more difficult Jigsaw Maul
as the project grows larger, while tapering stones to Circular saw 3
⁄4" plywood
fit is a greater challenge as the circle gets smaller. To Drill 1
⁄4" plywood
minimize the need for cutting and lifting stone, we Tape measure Wallboard screws
built this window two feet in diameter atop an existing Level (1 and 2")
stone wall. Before doing this, you’ll need to check with Chalk Tapered shims
your local building inspector regarding restrictions on Mortar box 2 × 4 and 2 × 8
wall height, footings, and other design considerations. Mason’s hoe lumber
You may need to modify the dimensions to conform Trowels 4 × 4 posts
with the local building code. Jointing tool or Type M mortar
Make sure to have at least one helper on hand. tuck-pointer (stiff mix)
Building with stone is always physically demanding, Mortar bag Ashlar stone
and steps such as installing the brace and form Stone chisel Eye protection and
(opposite page) require a helper. Mason’s string work gloves
A moon window is just about the most dramatic garden element you can build. We constructed the wall shown here using cut
ashlar mortared around a semicircular form, but using brick is also an option. Once the bottom half of the window has set up, the
form is flipped and the top stones are placed. The construction technique for the form is the same one used in building an arch
(pages 156 to 159).214 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build a Stone Moon Window 1 2
Build a plywood form, following the instructions on page Number each stone and a corresponding point on the form 157. Select stones for the top of the circle with sides that are using chalk, and then set the stones aside. Turn the form squared off or slightly tapered. Dry-lay the stones around the around, and label a second set of stones for the bottom of the outside of the form, spacing the stones with shims that are circle. Tip: To avoid confusion, use letters to label the bottom roughly 1⁄4” thick at their narrow end. set of stones instead of numbers.
3 4
1
⁄4" gapPrepare a stiff mix of Type M mortar Set the form on top of the stone and brace the form by constructing a sturdy and lay a 1⁄2”-thick mortar bed on top of 2 × 4 scaffold and secure it by constructing a bracing structure made from 4 × 4 posts the wall for the base of the circle. Center and 2 × 4 lumber. We used pairs of 2 × 4s nailed together for lengthwise supports. the stone that will be at the base of the Check the form for level in both directions and adjust the braces as required. Screw circle in the mortar. the braces to the form so the edges are at least 1⁄4” in from the edges of the form.
(continued)
Natural Stone ■ 215
5 6 7
Extend the mortar bed along the Attach mason’s string at the center Stagger the joints as you build
wall and add stones, buttering one end of the front and back of the form and upward and outward. Alternate large
of each stone and tapping them into use the strings to check the alignment and small stones for maximum
place with a trowel. Keep the joint width of each stone. strength and a natural look. Stop
consistent with the existing wall, but set occasionally to smooth joints that have
the depth of new joints at about 1" to hardened enough to resist minimal
allow for tuck-pointing. finger pressure.
8 9
Dress stones as necessary to follow large bulges or curves as Once you’ve laid stones about 1⁄2" beyond the top edge of
you lay stones around the circle. The sides should be roughly the form, disassemble the bracing.
squared off.216 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
10 11
Invert the form on top of the wall in preparation for laying the top half of the Lay stones around the circle, circle. The bottom edge of the form should be set roughly 1⁄2” higher than the top working from the bottom up, so the of the lower half of the circle. Check the braces for level (both lengthwise and top, or keystone, is laid last. If mortar widthwise), and adjust them as necessary and reattach them to the posts. oozes from the joints, insert temporary shims. Remove the shims after 2 hours and pack the voids with mortar.
12 13 14
Once the keystone is in place, smooth Remove any excess mortar from A putty-like consistency will develop the remaining joints. Remove the form. the joints inside the circle. Mist lightly, in joints. At this point, use a joining tool to Let the wall set up overnight, and then and then tuck-point all joints with stiff smooth the surface. Let the mortar harden mist it several times a day for a week. mortar so they are of equal depth. overnight. Mist the wall for 5 more days.
Natural Stone ■ 217
These convenient interlocking pavers are made with DIYers in mind. They are easy to install and often come with fully plotted
patterns for simple design preparation and installation.218 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Cobblestone Paver Patio
N ot technically natural stone, interlocking stone pavers have advanced by leaps and bounds from the monochromatic, cookie-cutter bricks and slabs driveways and busy walkways as well as backyard patios. If you prefer, you can set pavers into a mortar bed on a concrete slab. associated with first-generation concrete pavers. Note: The differences do not bear on the installation The latest products feature subtle color blends that process, but its helpful to distinguish between brick lend themselves well to organic, irregular patterns. A pavers and concrete pavers. Brick pavers are made of tumbling process during manufacturing can further age fired clay. Concrete pavers are cast from concrete that’s the pavers so they look more like natural cobblestones. placed in forms and cured. Natural cobblestones are The technological advances in the casting and finishing small stones with flat, smooth surfaces. processes have become so sophisticated that a well- selected concrete paver patio could look as comfortable in a traditional Tuscan village as in a suburban backyard. Tools & Materials ▸ When choosing pavers for a patio, pick a style and blend of shapes and sizes that complement your Wheelbarrow Water-cooled masonry landscape. Use your house and other stone or masonry Garden rake saw in the landscape to inform your decisions on colors 4-ft. level Plate compactor and shade. Be aware that some paver styles require Hand maul Gloves, ear protection, set purchase amounts, and it’s not always possible to Small pry bar and safety glasses return partly used pallets. Wood stakes Stiff bristle broom Here we lay a cobble patio that uses three sizes Chalk line 6 × 6 cobble squares of stone. These may be purchased by the band Mason’s string 6 × 9 cobble (a fraction of a pallet), minimizing leftovers. Line level rectangles Notice that an edge course creates a pleasing Shovel 3 × 6 cobble border around our patio. Bring a drawing of your Tape measure rectangles for edges patio with exact measurements to your stone yard. Square-nose spade Compactable gravel Based on your layout pattern, the sales staff will be 1”-dia. metal pipes Coarse sand able to tell you how much of each size stone you’ll Straight 2 × 4 Paver edging and need to purchase. 4 × 4 squares of spikes One great advantage to interlocking concrete plywood Joint sand pavers is that they create a very rigid surface with Particle mask Flathead screwdriver high resistance to movement and sinking, even when set on a gravel base. This makes them suitable for
Cobblestones ▸
Today, the word "cobblestone" more often
refers to cast concrete masonry units that
mimic the look of natural cobblestones.
Although they are tumbled to give them
a slightly aged appearance, cast concrete
cobbles are more uniform in shape, size, and
color. This is an advantage when it comes
to installation, but purists might object to
the appearance.
Natural Stone ■ 219
■ Pattern Detail: Cobblestone Patio
90º Basketweave Pattern
3 × 6"
6 × 6"
6 × 9"
■ Cross-Section: Cobblestone Patio
Paver edge Cobbles Jointing Sand Backfill
Sand
Gravel
Dirt
Landscape Sand 2" Compactable gravel
spike 4 to 6"220 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build a Cobblestone Paver Patio 1 2
Lay out the patio outline and set digging depth with grade Excavate the building site, paying close attention to the stakes. Factor a minimum 1” per 8 ft. of drainage slope away outlines and stakes that denote the excavation depth and slope. from the house if the patio is next to your home. Remove the strings.
3 4
Rake and screed the compactable gravel to follow the Lay out square corners for the patio with stakes and string, drainage slope and then compact with a plate compactor. starting next to an adjoining structure. Use the 3-4-5 method to check the intersecting lines for squareness at the corners.
(continued)
Natural Stone ■ 221
5 6
Paver edge spikes
Snap chalk lines directly below the outlines you’ve Strike off the coarse sand base by dragging a 2 × 4 screed
created with the mason’s strings and then install professional- across 1" pipes that are used as screed gauges.
grade paver edging at the lines. The paver edge should rest on
compacted gravel, not soil.
7 8
Bond line
A
Perpendicular
to bond line
B
Strings A and B are equal in
length to create right angles.
Begin laying out the cobbles, starting at the square corner. Tie additional strings to establish a guide line that bisects
Work in small sections on approximately 5 square ft. Simply set the project and is perpendicular to the bond line at the end
the cobbles into the sand base—do not adjust them from side of the layout pattern.
to side or try to reset the height.222 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Creating a Layout ▸
The number of purchasing options available when you
shop for pavers makes it possible to create just about
any patio layout pattern you can imagine. There is nothing
stopping you from going wild and creating a layout that’s
truly creative. However, most landscape centers are happy
to work with you to create a layout that employs tested
design ideas and consumes pavers in a very efficient
manner with as little cutting as possible.
Another option for DIY designers is to visit the website
of the paver manufacturer (you should be able to get the
information from your paver dealer). Many of these have
applications where you can choose a basic style you like
(such as the basketweave pattern seen here), and enter
size information. You’ll receive a printout of what the
pattern should look like along with a shopping list for the
materials you’ll need, all the way down to sand and spikes
for your paver edging. To see an example of a design
calculator/estimator, visit the website for Borgert Products,
maker of the cobbles seen here in a 30% square, 70%
rectangle basketweave pattern with rectangular border.9 10
Bond line
Paver edgingInstall the paver edging for the rest of the patio using Cut the cobbles to fit the layout using a wet saw the bond lines as reference. Brush sand out of the edging (rentable). installation area so the paver edging rests on the compactable base. Replace and smooth the sand after the edging is installed.
(continued)
Natural Stone ■ 223
11 12
Fill gaps between cobbles with decorative sand, such as Tamp the cobble stones with a plate compactor to bring
crushed granite, or with specially formulated jointing sand that them to level and seat them in the base. Add jointing sand in
hardens when dampened for a more formal look. the joints if levels drop as you work.
Making Curves ▸
At rounded corners and curves, install border pavers (below the paver edges so you don’t end up with wide gaps at the
left) in a fan pattern with even gaps between the pavers. outside. When using border pavers in a curved layout, the
Gentle curves may accommodate full-size border pavers, field pavers will need to be trimmed to fit the odd spaces
but for sharper turns you usually need to cut tapers into created where the field and borders intersect (below right).224 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Variation: Circular Paver Patio 1 2
Set the first ring of pavers around the center paver. Check Set the remaining pavers, completing each ring according their positions carefully, and make sure the spacing lugs are to your layout diagram. Be sure to offset the paver joints oriented correctly. If the pavers don’t have lugs, gap them between rows. The pavers may be labeled, requiring them to according to the manufacturer’s specifications. Note: Do not be installed in a specific order as you work around the circle. hammer or tamp the pavers into the sand bed unless the After a sizable area is laid, work from your plywood platform manufacturer directs otherwise. set atop the pavers.
3 4
Install rigid paver edging along the patio’s perimeter. Set the Inspect the paving to make sure all joints are aligned edging on top of the gravel sub-base but not the sand bed. Tip: properly and all gaps are consistent. Make minor adjustments Dampening the sand bed along the patio edge makes it easy to to pavers as needed using a flathead screwdriver as a pry bar. cut the sand away cleanly with a trowel before setting the edging. Be careful not to mar the paver edges as you pry.
Natural Stone ■ 225
Sandset flagstone patios blend nicely with natural landscapes. Although flagstone evokes a natural feel, the patio can appear
rustic or formal. This patio has clean, well-tamped joints and straight, groomed edges along the perimeter that lend a formal feel.
Plantings in the joints or a rough, natural perimeter would give the same patio a more relaxed, rustic feel.226 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Sandset Flagstone Patio
F lagstones make a great, long-lasting patio surface with a naturally rough texture and a perfectly imperfect look and finish. Randomly shaped stones landscape fabric under your sand base to discourage weed growth. The following project includes steps for building a are especially suited to patios with curved borders, but classic flagstone patio. You’ll also find instructions for they can also be cut to form straight lines. Your patio building low dry stone walls, the ultimate add-on to a will appear more at home in your landscape if the stone patio surface. If you’re new to working with natural flagstones you choose are of the same stone species stone, see pages 177 to 179 for some basic cutting tips. as other stones in the area. For example, if your gravel paths and walls are made from a local buff limestone, look for the same material in limestone flags. Tools & Materials ▸ Flagstones usually come in large slabs, sold as flagstone, or in smaller pieces (typically 16” or Mason’s string Stiff-bristle brush smaller), sold as steppers. You can make a patio out Line level Circular saw with of either. Larger stones will make a solid patio with Rope or hose masonry blade a more even surface, but the bigger ones can require Excavation tools Plugs or seeds for three strong people to position, and large stones are Spud bar ground cover hard to cut and fit tightly. If your soil drains well and Broom Eye and ear is stable, flagstones can be laid on nothing more than Stakes protection a layer of sand. However, if you have unstable clay Marking paint Work gloves soil that becomes soft when wet, start with a four- 1” (outside 3 ⁄4” plywood inch-thick foundation of compactable gravel under diameter) pipe 31⁄2” deck screws your sand. Coarse sand Pointing chisel There are a few different options for filling the Straight 2 × 4 Pitching chisel spaces between flagstones. One popular treatment is Flagstone Stone chisel to plant them with low-growing perennials suited to Spray bottle Hand maul crevice culture. For best results, use sand-based soil Stone edging Dust mask between flagstones when planting. Also, stick to very Sand-based soil or Chalk or a crayon small plants that can withstand foot traffic. Another joint sand Square-nose spade option is to create a rock garden effect by eliminating Lumber (2 × 2, Crushed stone an occasional small flag in an out-of-the-way spot and 2 × 4) Ashlar planting the space with a sturdy accent species. If Drill Mortar you prefer not to have a planted patio, simply fill the Mason’s trowel Capstones joints with sand or fine gravel—just be sure to add
Adding a Stone Wall ▸
A dry stone wall is a simple,
beautiful addition to a flagstone
patio. A wall functions as extra
seating, a place to set plants,
or extra countertop or tabletop
space. It also provides visual
definition to your outdoor space.
See page 182 for how to build a
stone wall.
Natural Stone ■ 227
Construction Details: Sandset Flagstone Patio
1"
Lay flagstones so their tops are approximately
1
⁄2 to 1" above the surrounding ground. Because
natural stones are not uniform in thickness, you
will need to adjust sand or dirt beneath each
flagstone, as needed.
Gaps filled with
sand-based soil,
sand, or gravel
2 to 3" thick Coarse sand: 2 to 4"
Optional compacted
Backfill with sand gravel: 4 to 6"
A typical sandset patio has a layer of coarse sand for embedding the flagstones. A sub-base of compactable gravel is
an option for improved stability and drainage. The joints between stones can be filled with sand, gravel, or soil and plants.
Edging material is optional.
Flagstones that are
cut into rectangular
Irregular flagstones shapes can be laid in
look natural and are square or rectangular
easy to work with in patterns with
round layouts. uniform gaps.228 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build a Sandset Flagstone Patio 1 2
Outline the patio base using string and stakes for straight Set up layout strings to guide the excavation using stakes or lines and/or a rope or hose for curves. The base should extend batterboards (see pages 38 to 41 for detailed steps on layout at least 2 to 4” beyond the edges of the flagstones, except and site preparation). Excavate the base to a depth of 2” plus where the patio will butt up to a wall. Transfer the outline to the stone thickness plus 1⁄2 to 1”. Slope the ground away from the ground with marking paint. Remove any sod and vegetation the house foundation at a rate of 1⁄4” per ft. within the base area.
3 4
Screed
GaugesLay sections of 1” pipe across the project area to serve Fill the site with coarse sand slightly above the screed as screed gauges. These allow you to strike off sand at a gauges. With a helper, drag a straight 2 × 4 across the screed consistent depth when you drag a screed board over them. gauges to level off the sand. Use a screed board that’s long Note: Since large flagstones can be held in place adequately enough so that you can avoid stepping in the sand. Work the by the surrounding soil, edging for the patio is optional; it often screed in a back-and-forth sawing motion. Remove the pipes looks best to allow neighboring ground cover to grow up to the once each section is finished, fill in the voids, and smooth the edges of the stones. If you do plan to use edging, install it now. surface flat.
(continued)
Natural Stone ■ 229
5 6
Arrange your flagstones into groups according to size and Begin by laying large, thick stones around the perimeter
shape. As a general rule, start paving with the broadest stones of the patio. Leave a consistent gap of about 1" between
and fill in around them with increasingly smaller pieces, but stones by matching pieces like a puzzle and cutting and
appearance and sight lines are also important: If there is one dressing stones as needed (see pages 177 to 179). The outer
nice stone with a flat surface and good color, feature it in the edge of the patio should form smooth curves (or straight lines)
center of the patio. Or, if some of the patio will be visible from without jutting pieces or abrupt irregularities. Level stones as
the house, choose nicer stones for these areas. needed by prying up with a spud bar and adding or removing
sand underneath.
7 8
Fill in around the larger stones with smaller pieces cut to Fill the joints between stones with sand-based, weed-
fit the spaces, as needed, working from the outside in. After seed-free soil (see page 231). Sweep the soil across the patio
setting a band of stones a few courses wide, lay a 2 × 4 across surface to fill the cracks, and then water the soil so it settles.
the stones to make sure they’re level with one another. Add Repeat as needed until the soil reaches the desired level.
or remove sand below to adjust their height and dampen the Plant plugs or seeds for ground cover to grow up between the
sand occasionally to make it easier to work with. stones, if desired.230 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Variation: To finish the patio with sand instead of soil and plants, spread sand over the patio and sweep across the stones with a push broom to fill the joints. Pack the sand with your fingers or a piece of wood. Spray the entire area with water to help compact the sand. Let the patio dry. Repeat filling and spraying until the joints are full and the stones are securely locked in place.
Choosing Soil & Plants for Your Patio ▸
Sand-based soil (also called “patio planting” soil)
is the best material to use for planting between
flagstones. This mixture of soil and sand sweeps
easily into joints, and it resists tight compaction to
promote healthy plant growth, as well as surface
drainage. Regular soil can become too compacted
for effective planting and drainage and soil from
your yard will undoubtedly contain weeds. Sand-
based soil is available in bulk or by the bag and is
often custom-mixed at most large garden centers.
As for the best plants to use, listed below
are a few species that tend to do well in a patio
application. Ask a local supplier what works best
for your climate.
• Alyssum • Saxifrage
• Rock cress • Sedum
• Thrift • Thymus
• Miniature dianthus • Scotch moss
Patio “planting soil” (for planting between stones) is available
• Candytuft • Irish moss
in bulk or bags at most garden centers. It is good for filling
• Lobelia • Woolly thyme cracks because the sand base makes it dry and smooth enough
• Forget-me-not • Mock strawberry to sweep into cracks, yet the black compost will support plant
growth. Because it is bagged, you can be assured it doesn’t come
with weeds.
Natural Stone ■ 231
Pebbled Stepping Stone Path
S tepping stones in a path do two jobs: they lead
the eye and they carry the traveler. In both cases
the goal is rarely fast direct transport, but more of a
relaxing meander that’s comfortable, slow-paced, and
above all natural. Arrange the stepping stones in a
walking path according to the gaits and strides of the
people most likely to use the pathway. Realize that
our gaits tend to be longer on a utility path than in a
rock garden.
Sometimes steppers are placed more for visual
effect, with the knowledge that they will break the
pacing rule with artful clusters of stones. Clustering
is also an effective way to slow or congregate walkers
near a Y in the path or at a good vantage point for a
striking feature of the garden.
Choose steppers and pebbles that are
complementary in color. Shades of medium to dark
gray are a popular combination for a Zen feeling. Too
much contrast or very bright colors tend to undermine
the sense of tranquility a pebbled stepping stone path
can achieve.
Tools & Materials ▸
1 × 3 stakes Edging/trenching
Lumber (1 × 2, 2 × 4) spade
Mason’s string Flat-nosed spade
Mallet Hand tamper
Hose or rope Work gloves
Landscaping paint
Measuring tape
Edging
Spun-bonded
landscape fabric
Sod stripper
Coarse sand
Thick steppers or
broad river rocks
with one flat face
¼ to ½" pond
pebbles
2½"-dia. river rock
Wheelbarrow
Stepping stones blend beautifully into many types of
Round-nosed spade
landscaping, including rock gardens, ponds, flower or
vegetable gardens, or manicured grass lawns.232 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Build a Pebbled Stepping Stone Path 1 2
Excavate the pathway site and prepare a foundation. Level the stones by adding and removing sand until they are Substitute coarse building sand for compactable gravel. Strike solidly seated. On flat runs, you should be able to rest a flat the sand to a consistent depth with a notched 2 × 4. 2 × 4 on three stones at once, making solid contact with each. It is much easier to pack sand under stones if you moisten the sand first. Also moisten the sand bed to prevent sand from drifting.
3 4 5
Spread out a layer of the largest Add the smallest size infill stones Place the remaining larger-diameter diameter rock if you are using two or last, spreading them evenly so you do infill stones around the surface of the more series of infill. not have to rake them much. walkway to enhance the visual effect of the pathway.
Natural Stone ■ 233
Zen Garden Tools & Materials ▸
Stakes Excavating tools
Mason’s string Hand maul
W hat’s commonly called a Zen garden in the
West is actually a Japanese dry garden, with
little historical connection to Zen Buddhism. The
Garden hose
Landscape marking
Manual tamper
Spun-bonded
form typically consists of sparse, carefully positioned paint landscape fabric
stones in a meticulously raked bed of coarse sand or Straight 2 × 4 Fieldstone steppers
fine gravel. Japanese dry gardens can be immensely Level Specimen stones
satisfying. Proponents find the uncluttered space Measuring tape Border stones or
calming and the act of raking out waterlike ripples in Compactable gravel blocks
the gravel soothing and perhaps even healing. The fact Crushed granite Eye protection and
that they are low maintenance and drought resistant is (light colored) work gloves
another advantage.
Site your garden on flat or barely sloped ground
away from messy trees and shrubs (and cats), settle out immediately. Crushed granite is a viable
as gravel and sand are eventually spoiled by the medium. Another option that is used occasionally is
accumulation of organic matter. There are many turkey grit, a fine gravel available from farm supply
materials you can use as the rakable medium for the outlets. In this project, we show you how to edge
garden. Generally, lighter-colored, very coarse sand is your garden with cast pavers set on edge, although
preferred—it needs to be small enough to be raked you may prefer to use natural stone blocks or even
into rills yet large enough that the rake lines don’t smooth stones in the four to six inches range.
A Zen garden is a small rock garden, typically featuring a few large specimen stones inset into a bed of gravel. It gets its name
from the meditative benefits of raking the gravel.234 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Make a Zen Garden 1 2
Lay out the garden location using stakes and string or Excavate the site and install any large specimen stones that hoses and then mark the outline directly onto the ground with require burial more than 1⁄2 ft. below grade. landscape paint.
3 4
Dig a trench around the border for the border stones. Pour a 3” thick layer of compactable gravel into the border trench and tamp down with a post or a hand tamper.
(continued)
Natural Stone ■ 235
5 6
Place border blocks into the trench and adjust them so the Test different configurations of rocks in the garden to find
tops are even. an arrangement you like. If it’s a larger garden, strategically
place a few flat rocks so you can reach the entire garden with
a rake without stepping in the raking medium.
7 8
Set the stones in position on individual beds of sand about Rake the medium into pleasing patterns with a special rake
1" thick. (see next page).236 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
How to Make a Zen Garden Rake ▸ Once you have constructed your Zen garden, you will use two tools to interact with it: your eyes and a good rake. While any garden rake will suffice for creating the swirling and concentric rills that are hallmarks of the Zen garden, a special rake that’s dedicated to the garden will enhance your hands-on interaction. Many Zen garden rakes are constructed from bamboo. Bamboo is lightweight and readily available, especially through internet sites. While you can certainly choose this material, you’re likely to find that the lightness can actually work against it, causing you to exert more strain to cut through the raking medium. A rake made from solid wood has greater heft that lets it glide more smoothly through the medium. The rake shown here is made using only the following materials:
• 1¼”-dia. by 48” oak or pine dowel (handle) • ½” by 36” oak or pine dowel (tines) • 2 × 3 × 9½” piece of red oak (head)
Figure 1 Figure 2 Figure 3
Here is how to make it. Start by sanding all of the stock Cut four 5”-long pieces of the ½”-dia. oak doweling for very smooth using sandpaper up to 150 grit in coarseness. the tines. Apply wood glue into the bottom of each hole Soften the edges of the 2 × 3 with the sandpaper. Drill a and insert the tines, setting them by gently tapping with 1¼” dia. hole in the head for the handle (Figure 1). The a wood mallet (Figure 2). Then, apply glue to the handle hole should go all the way through the head at a 22½° holes sides and insert the handle so the end protrudes all downward angle (half of a 45° angle), with the top of the the way through. After the glue dries, drill a ½”-dia. hole hole no closer than ¾” to the top of the head. Use a backer down through the top of the head and into the handle. board when drilling to prevent blowout and splinters. Glue a ½” dowel into the hole to reinforce the handle (this Next, drill ½”-dia. by 1”-deep seat holes for the tines is called pinning). in the bottom edge of the blank. Locate centers of the two Finally, use a back saw, gentleman’s saw, or Japanese end holes 1” from the ends. Measure in 2½” from each flush-cutting saw to trim the handle end and the handle pin end hole and mark centers for the intermediate tines. Use flush with the head (Figure 3). Sand to smooth the trimmed masking tape to mark a drilling depth of 1” on your drill ends and remove any dried glue. Finish with two or three bit and then drill perpendicular holes at each centerline. light coats of wipe-on polyurethane tinted for red oak.
Natural Stone ■ 237Decorative Masonry Finishing A dd textural interest to masonry surfaces with stains, stucco, veneer, and other decorative applications that dress up a project. You’ll learn skills for dressing up basic concrete and how to use stone as the icing on your project. The techniques in this chapter can be applied to many of the projects in this book.
In this chapter: • Stamped Concrete Finishes • Acid-stained Concrete Patio • Decorative Concrete Floor • Stucco Finish • Stone Veneer • Mortarless Brick Veneer Siding • Tiling a Slab • Tiling a Concrete Slab • Tiling Concrete Steps
■ 239
Stamped Concrete Finishes
S tamped finishes can bring interesting texture to
ordinary concrete sidewalks, patios, and driveways.
Stamping mats are available in a variety of textures and
Professional
grade
patterns, and they can be rented at most equipment
rental centers and concrete supply stores.
As you plan your concrete project, also plan
the layout of the stamping mats to help maintain a
consistent pattern across the project. For best results,
mark a reference line at or near the center of the project
and align the first mat with it. Align the subsequent DIY friendly
mats with the first, working outward toward the ends of
the project. Plan for long seams to fall across the project
rather than along the length of it to avoid misaligned
seams. You may have to hand-finish textures at corners,
along sides, or near other obstructions using specialty
stamps or an aluminum chisel.
The stamping pads should be pressed into
Stamping mats can be pressed onto fresh concrete, as with
slightly stiff concrete to a depth of about one inch. the professional-grade mats in the larger photo above (these
Professionals typically use enough pads to cover the are fairly expensive). DIY-oriented stamping mats are cheaper
entire project area. For DIYers, it probably makes more but offer fewer options. The DIY mats are usually open grids, so
sense to have one or two pads and reuse them. they can be used as either stamp pads or molds.
Tools & Materials ▸
Tools for mixing and Textured stamping Materials for mixing, Pressure washer
pouring concrete mats pouring, and Powder release agent
Hand tamp Aluminum chisel coloring concrete Work gloves
Stamped concrete can emulate the appearance of expensive imported stones or just about any other paver, but at a much lower cost.240 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Stamp a Concrete Surface 1 2
Pour a concrete slab and mark a reference line for the first mat Align the first stamping mat with the reference line on the at or near the center of the form. When the bleed water disappears form, following your layout plan. Once the mat is placed, do from the surface, toss powder release agent across the surface in not adjust it. Carefully step onto the mat or use a hand tamp to the amount specified in the manufacturer’s instructions. embed the stamp into the concrete.
3 4
Butt the second pad against the first, so the seams are flush After the concrete has cured for three days, remove leftover and aligned. Embed the mat into the concrete, and then place a release agent from the surface using a pressure washer with a third mat, maintaining the continuous pattern. Remove and reuse wide-fan spray—work in smooth, even strokes no more than 24” mats. When the project area is wider than the stamping pads, from the surface. Allow the concrete to cure fully for an additional complete rows across the width before stamping lengthwise. week, and then apply an acrylic concrete sealer according the manufacturer’s instructions. Remove the forms and backfill.
Decorative Masonry Finishing ■ 241
Acid-stained Concrete Patio
A cid staining is a permanent color treatment for
cured concrete that yields a translucent, attractively
mottled finish ideally suited to patios. Unlike paint or
Another important preparation step with either
new or old concrete is to color-test a few shades of
stain on the concrete you’ll be working with. Stain
pigmented concrete stains, both of which are surface suppliers often sell sample-size quantities of stain for
coatings, acid stain is a chemical solution that soaks this purpose. Since acid stain affects every surface
into the concrete pores and reacts with the minerals to a little differently, it’s worth the effort to run a test
create the desired color. The color doesn’t peel or flake before committing to a color. Be sure to test in
off, and it fades very little over many years. Acid stain an inconspicuous area, because the stain can’t be
won’t hide blemishes or discoloration in the original removed once it’s applied.
concrete surface, but many consider this an important
part of its natural appeal. If your patio or walkway is fully
exposed, bear in mind that some colors of acid stain Tools & Materials ▸
may fade in direct sunlight, so be sure to choose a color
guaranteed by the manufacturer not to fade. Tape Eye protection
You can apply acid stain to new concrete that has Plastic sheeting NIOSH/MSHA-
cured for at least four to six weeks (check the stain manu- Stiff-bristled brush approved respirator
facturer’s requirements for curing times) or old concrete Concrete cleaner Cleaner/neutralizer
that is free of any previously applied sealants. Test old and solvent Medium-bristled
concrete by spraying the surface with water: If the water All-plastic garden scrub brush
beads on the surface instead of soaking in, there’s prob- sprayer Towel
ably a sealer on there, and it must be removed for good Stain Sealer
results with the stain. Ask the stain manufacturer for Protective clothing
recommended concrete sealer remover products to use.
Acid-staining a patio is a fairly simple procedure that can be done by almost anyone. Be sure the surface is completely cured,
clean (use water, not soap), and dry; and be sure to wear the protective gear, as recommended by the manufacturer. A properly
maintained acid-stained patio can last forever.242 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Apply an Acid Stain 1 2 3
Protect all surfaces adjacent to the concrete and any nearby plants with tape and plastic sheeting.
Clean the entire surface with an Spray the stain onto the concrete
approved cleaner and stiff-bristled brush. using random circular motions and
Warning ▸ Mix the stain with water in an all-plastic holding the spray tip about 18" from the
garden sprayer, as directed. Use an surface. Work backward from one side.
approved solvent to remove undesirable Maintain pressure on the sprayer so the
Always pour acid stain into
markings on the concrete surface (stain spray pattern is consistently fine and
water; never pour water into won’t hide them). Rinse thoroughly and even. Wet the surface completely, but
acid stain. then let dry. avoid creating puddles. Allow the first
coat of stain to dry completely.4 5 6
Apply a second coat using the same Wash the surface using a Apply sealer using a high-quality deck/ technique. Darker tones will appear with recommended cleaner/neutralizer patio sprayer (or other recommended the second coat; the wetter the surface, and a medium-bristled scrub brush to applicator). Follow the manufacturer’s the darker the tones will be (but again, remove dried stain residue. Thoroughly instructions and recommendations— avoid puddles of stain). Let the second rinse according to the manufacturer’s most sealers require multiple coats. coat dry completely. instructions. Test-wipe the surface with Maintain even pressure on the sprayer a white towel: If the towel shows stain, for a consistently fine spray. Wet the wash and rinse the surface again. surface completely with a thin coating, and avoid puddles. Let the sealer dry between coats.
Decorative Masonry Finishing ■ 243
Decorative Concrete Floor
M ost people are accustomed to thinking of
concrete primarily as a utilitarian substance, but
it can also mimic a variety of flooring types and be a
Tools & Materials ▸
colorful and beautiful addition to your basement room. Concrete cleaner High-pressure washer
Concrete is a hard and durable building material, Acid-tolerant pump Paintbrush
but it is also porous—so it is susceptible to staining. sprayer Respirator
Many stains can be removed with the proper cleaner, Alkaline-base neutralizer Stiff-bristle broom
but sealing and painting prevents oil, grease, and other Sealant and brush
stains from penetrating the surface in the first place; Rubber boots Extension handle
and cleanup is a whole lot easier. Rubber gloves
Even after degreasing a concrete floor, residual Roller tray
grease or oils can create serious adhesion problems for Wet vacuum
coatings of sealant or paint. To determine whether your Acid-tolerant bucket
floor has been adequately cleaned, pour a glass of water Eye protection and
on the concrete floor. If it is ready for sealing, the water work gloves
will soak into the surface quickly and evenly. If the Garden hose with nozzle
water beads, you may have to clean it again. Detergent Paint roller and tray
used in combination with a steam cleaner can remove Primer
stubborn stains better than a cleaner alone. Painter’s tape
There are four important reasons to seal your Plastic sheeting
concrete floor: to protect the floor from dirt, oil, Garden sprayer
grease, chemicals, and stains; to dust-proof the Concrete stain
surface; to protect the floor from abrasion and sunlight Soft-woven roller cover
exposure; and to repel water and protect the floor
from freeze-thaw damage.
Etching and sealing a concrete floor
that is in good condition yields a slick-
looking surface that has a contemporary
feel and is easy to maintain.244 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Seal Concrete Basement Floors 1 2
Clean and prepare the surface by first sweeping up all Saturate the surface with clean water. The surface needs debris. Next, remove all surface muck: mud, wax, and grease. to be wet before acid etching. Use this opportunity to check Finally, remove existing paints or coatings. for any areas where water beads up. If water beads on the surface, contaminants still need to be cleaned off with a suitable cleaner or chemical stripper.
3 4
Test your acid-tolerant pump sprayer with water to make Add the acid-etching contents to the water in the acid- sure it releases a wide, even mist. Once you have the spray tolerant pump sprayer. Follow the directions (and mixing nozzle set, check the manufacturer’s instructions for the proportions) specified by the manufacturer. Use caution and etching solution and fill the pump sprayer (or sprinkling can) wear safety equipment. with the recommended amount of water. (continued)
Decorative Masonry Finishing ■ 245
5 6
Apply the acid solution. Using the sprinkling can or acid- Use a stiff-bristle broom or scrubber to work the acid
tolerant pump spray unit, evenly apply the diluted acid solution solution into the concrete. Let the acid sit for 5 to 10 minutes,
over the concrete floor. Do not allow acid solution to dry at any or as indicated by the manufacturer’s directions. A mild
time during the etching and cleaning process. Etch small areas foaming action indicates that the product is working. If no
at a time, 10 × 10 ft. or smaller. If there is a slope, begin on the bubbling or fizzing occurs, it means there is still grease, oil, or
low side of the slope and work upward. a concrete treatment on the surface that is interfering. If this
occurs, follow steps 7 to 12 and then clean again.
7 8
Once the fizzing has stopped, the acid has finished Use a garden hose with a pressure nozzle or, ideally, a
reacting with the alkaline concrete surface and formed pH- pressure washer in conjunction with a stiff-bristle broom to
neutral salts. Neutralize any remaining acid with an alkaline- thoroughly rinse the concrete surface. Rinse the surface two
base solution. Put 1 gal. of water in a 5-gal. bucket and then to three times. Reapply the acid (repeat steps 5, 6, 7, and 8).
stir in an alkaline-base neutralizer. Using a stiff-bristle broom,
make sure the concrete surface is completely covered with
the solution. Continue to sweep until the fizzing stops.246 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
9 10
If you have any leftover acid, you can make it safe for your Use a wet/dry vacuum to clean up the mess. Some septic system by mixing more alkaline solution in the 5-gal. sitting acids and cleaning solutions can harm local bucket and carefully pouring the acid from the spray unit into vegetation, damage your drainage system, and are just the bucket until all of the fizzing stops. plain environmentally unfriendly. Check your local disposal regulations for proper disposal of the neutralized spent acid.
11 12
To check for residue, rub a dark cloth over a small area of Let the concrete dry for at least 24 hours and sweep up concrete. If any white residue appears, continue the rinsing dust, dirt, and particles leftover from the acid-etching process. process. Check for residue again. Your concrete should now have the consistency of 120-grit sandpaper and be able to accept concrete sealants.
Decorative Masonry Finishing ■ 247
■ How to Stain a Concrete Floor
1 2
Thoroughly clean the entire floor (see page 165). Use Dampen the floor with water using a garden sprayer. Mop
painter’s tape and plastic sheeting to protect any areas that up any pooled water, but make sure the entire floor is damp.
won’t be stained, as well as surrounding walls and other Load sprayer with stain, and then apply the stain evenly in a
surfaces. Test the spray of your garden sprayer using water: It circular motion until the concrete is saturated. Let the floor dry.
should deliver a wide, even mist.
3 4 5
Remove the etching residue by When the floor has dried completely Using a 3⁄8" nap roller, apply
soaking the floor with water and (at least 18 to 24 hours), begin applying the sealer in 2 × 6-ft. sections,
scrubbing vigorously with a stiff-bristled the sealer along the edges and in any maintaining a wet edge to prevent lap
brush. As you work, clean up the hard-to-reach areas using a paintbrush. marks. If the sealer rapidly sinks into
liquid with a wet/dry vacuum. Dispose the concrete, apply a second coat after
of the waste liquid safely, according to 2 hours. Let the floor dry for 18 to 24
local regulations. hours before allowing light foot traffic
and 72 hours before heavy use.248 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Paint a Concrete Floor 1 2
If you expect to use more than one container of paint, Using a nylon brush, such as a 2½” sash brush, cut in the open them all and mix them together for a uniform color. You sides and corners with primer. This creates a sharp, clean edge. do not need to thin a paint for use on a floor, unless you use a Start this way for the top coat as well. sprayer that requires thinned paint.
3 4
Using a roller pad with the nap length recommended by the With a clean roller pad, apply the first top coat. Make the manufacturer, apply a primer coat to the surface. Start at the top coat even but not too thick, and then let it dry for 24 corner farthest away from the door and back up as you work. hours. If you choose to add another top coat, work the roller in Allow the primer to dry for at least 8 hours. another direction to cover any thin spots. Let the final coat dry another day before you walk on it.
Decorative Masonry Finishing ■ 249
Stucco Finish
P rized for its weather resistance, durability, and
timeless beauty, stucco has long been one of the
most popular exterior wall finishes. As a building
material, stucco is essentially an exterior plaster made
of Portland cement, sand, and water. Other ingredients
may include lime, masonry cement, and various special
additives for enhancing properties like crack resistance,
workability, and strength. With a few exceptions, stucco
is applied much as it has been for centuries—a wet
mix is troweled onto the wall in successive layers with
the final coat providing the finished color and any
decorative surface texture desired.
The two traditional stucco systems are the three-
coat system used for standard wood-framed walls Stucco is one of the most durable and low-maintenance wall
and the two-coat system used for masonry walls such finishes available, but it requires getting each stage of the
as brick, poured concrete, and concrete block. And installation right, as well as the mix of the stucco itself.
today, there’s a third process—the one-coat system—
which allows you to finish standard framed walls
with a single layer of stucco, saving you money and
considerable time and labor over traditional three-coat Tools & Materials ▸
applications. Each of these systems is described in
detail on the opposite page. Aviation snips Texturing tools
The following pages show you an overview of Stapler Heavy-duty staples
the materials and basic techniques for finishing a Hammer 11⁄2" galvanized
wall with stucco. While cladding an entire house Level roofing nails
or addition is a job for professional masons, smaller Cement mixer Self-furring
projects and repair work can be much more doable Wheelbarrow galvanized metal
for the less experienced. Fortunately, all the stucco Mortar hawk lath (min. 2.5 lb.)
materials you need are available in a dry preblended Square-end trowel Metal stucco edging
form, so you can be sure of getting the right blend Raking tool Flashing
of ingredients for each application. During your Darby or screed Stucco mix
planning, consult with the local building department board Nonsag polyurethane
to learn about requirements for surface preparation, Wood float sealant
fire ratings for walls, control joints, drainage, and other Grade D building Work gloves
critical factors. paper
Base Coat Stucco Calculator ▸
Square feet 10 25 100 300 500
3
⁄8" thick – # of 80-lb. bags 1 1 4 12 19
1
⁄2” thick – # of 80-lb. bags 1 2 6 16 26
3
⁄4” thick – # of 80-lb. bags 1 2 8 24 38
All yields are approximate and do not allow for waste or uneven substrate, etc.250 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Stucco Systems ▸ Three-coat stucco is the traditional application for stud- Insulation Studs framed walls covered with plywood, oriented strand board (OSB), or rigid foam insulation sheathing. It starts with two layers of Grade D building paper for a moisture barrier. The wall is then covered with self-furring, expanded metal lath fastened to the framing with galvanized nails. Building Plywood paper sheathing Metal lath The scratch coat is the first layer of stucco. It is pressed into the lath, and then smoothed to a flat layer about 3⁄8” thick. While still wet, the stucco is “scratched” with a raking tool to create horizontal keys for the next layer to adhere to. Scratch coat The brown coat is the next layer. It’s about 3⁄8”-thick and brings the wall surface to within 1⁄8” to 1⁄4” of the finished Brown thickness. Imperfections here can easily telegraph through coat
the thin final coat, so the surface must be smooth and flat. To provide tooth for the final layer, the brown coat is finished with a wood float for a slightly roughened texture. Finish Coat The finish coat completes the treatment, bringing the surface flush with the stucco trim pieces and providing the color and decorative texture, if desired. There are many options for texturing stucco; a few of the classic ones are shown on page 255. Base Coat
Two-coat stucco is the standard treatment for masonry walls. This system is the same as a three-coat treatment but without a scratch coat. The base coat on a two-coat system is the same as the brown coat on a three-coat system. For the base coat to bond well, the masonry surface must be clean, unpainted, and sufficiently porous. Finish Coat You can test this by spraying water onto the surface: If the water beads and runs down the wall, apply bonding adhesive before applying the base coat, or you can fasten self-furring metal lath directly to the wall, and then apply a full three-coat stucco treatment.
One-coat stucco is a single-layer system for finishing framed walls prepared with a waterproof barrier and metal lath (as with a three-coat system). This treatment calls for one-coat, fiberglass-reinforced stucco, a special formulation that contains 1⁄2” alkali-resistant fiberglass fiber and other additives to combine high-performance characteristics with greatly simplified application. This stucco is applied in a 3⁄8- to ⁄8”-thick layer using standard techniques. QUIKRETE One 5
Coat Fiberglass Reinforced Stucco meets code requirements for a one-hour firewall over wood and form systems.
Decorative Masonry Finishing ■ 251
Texturing with Stucco ▸
Finding the right blend of ingredients and mixing to the proper consistency are critical to the success of any stucco
project. Premixed stucco eliminates the guesswork by giving you the perfect blend in each bag, along with mixing and
curing instructions for a professional-quality job. All of the stucco products shown here are sold in complete form,
meaning all you do is add water before application. Be sure to follow the mixing and curing instructions carefully for
each product.
Base coat stucco: Use this premixed stucco for
both the scratch and brown coats of a three-coat
application or for the base coat of a two-coat system.
You can apply the mixed stucco with a trowel or an
approved sprayer. Available in 80-pound bags in gray
color. Each bag yields approximately 0.83 cubic foot
or an applied coverage of approximately 27 sq. ft. at
3
⁄8" thickness.
Finish coat stucco: Use this stucco for the finish
coat on both three-coat and two-coat systems.
You can also use it to create a decorative textured
finish over one-coat stucco. Apply finish coat stucco
to a minimum thickness of 1⁄8", and then texture the
surface as desired. Available in gray and white for
achieving a full range of colors (see below). Coverage
of 80-pound bag is approximately 70 square feet at
1
⁄8" thickness.
One-coat, fiberglass-reinforced stucco:
Complete your stucco application in one step with
this convenient all-in-one stucco mix. You can texture
the surface of the single layer or add a top coat of
finish coat stucco for special decorative effects.
Available in 80-pound bags. An 80-pound bag covers
approximately 25 square feet of wall at 3⁄8" thickness.
Stucco and mortar color: Available in many
colors, stucco and mortar color is a permanent liquid
colorant that you blend with the stucco mix before
application. Some colors are for use with gray stucco
mix, while many others are compatible with white
mix. For best results, combine the liquid colorant with
the mixing water before adding the dry stucco mix,
and then blend thoroughly until the color is uniform.252 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Prepare Framed Walls for Stucco 1 2
Attach building paper over exterior wall sheathing using Install self-furring expanded metal lath over the building heavy-duty staples or roofing nails. Overlap sheets by 4”. paper with staples or 11⁄2” galvanized roofing nails (don’t use Usually, two layers of paper are required or recommended; aluminum nails) driven into the wall studs every 6”. Overlap consult your local building department for code requirements sheets of lath by 1” on horizontal seams and 2” on vertical in your area. seams. Install the lath with the rougher side facing out.
3 4
Install metal edging for clean, finished lines at vertical edges Use aviation snips to trim sheets of lath or cut edging of walls. Install casing bead along the top of stuccoed areas materials to length. Cut lath and edging can be very sharp, so and weep screed (or drip screed) along the bottom edges, as always wear gloves when working with these materials. applicable. Make sure all edging is level and plumb, and fasten it with galvanized roofing nails. Add flashing as needed over windows and doors.
Decorative Masonry Finishing ■ 253
■ How to Finish Walls with Stucco
1 2
For a three-coat system, mix the stucco to a trowel-able After moist-curing the scratch coat for 24 to 48 hours, mix
consistency and apply it with a square trowel, working from stucco for the brown coat (or base coat for two-coat system)
the bottom up. Press the stucco into the lath, and then screed and apply it in a 3⁄8"-thick layer. Use a straight board or a darby
and smooth the surface for a uniform thickness. When the coat to screed the surface so it’s flat and even. When the stucco has
hardens enough to hold a finger impression, scratch 1⁄8"-deep lost its sheen, float it with a wood float to roughen the surface.
horizontal grooves into the surface with a raking tool. Moist-cure the coat for 48 hours as directed.
3
Variation: For a one-coat application, mix a fiber-reinforced Mix the finish coat and apply it in a 1⁄8"-thick (minimum)
one-coat stucco and apply it in a 3⁄8 to 5⁄8"-thick layer, working layer, working from the bottom up. Complete large sections
from the bottom up and forcing it in to completely embed the or entire walls at one time for color consistency. Texture the
lath. Screed the surface flat with a darby or board. When the surface as desired. Cure the coat as directed. Seal all joints
surface loses its sheen, finish trowel or texture the surface around building elements with polyurethane sealant.
as desired. Cure the coat as directed. Seal all joints around
building elements with polyurethane sealant.254 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Finish Stucco 1 2
Test the coloring of finish stucco by adding different Mix the finish batch so it contains slightly more water than proportions of colorant and mix. Let the samples dry to see the scratch and brown coats. The mix should still stay on the their true finished color. For the application batches, be sure to mortar hawk without running. use the same proportions when mixing each batch.
Finish Option: Cover a float with Finish Option: Achieve a wet-dash Finish Option: For a dash-trowel carpet to make an ideal tool for finish by flinging, or dashing, stucco texture, dash the surface with stucco achieving a float-finish texture. onto the surface. Let the stucco cure using a whisk broom (left), and then Experiment on a small area. undisturbed. flatten the stucco by troweling over it.
Decorative Masonry Finishing ■ 255
Stone Veneer
W hether you use natural or manufactured veneer,
wet each stone, and then apply mortar to the
back before pressing it onto the mortared wall. Wetting
Tools & Materials ▸
and mortaring a stone (called buttering) results in Hammer or staple 15# building paper
maximum adhesion between the stone and the wall. gun Mortar color
The challenge is to arrange the stones so that large and Drill (optional)
small stones and various hues and shapes alternate Wheelbarrow 11⁄2” (minimum)
across the span of the wall. Hoe galvanized
This project is designed for installing veneer stone Square-end trowel roofing nails or
over plywood sheathing, which has the strength to Circular saw heavy-duty staples
support layers of building paper. If your walls are Dust mask 2 × 4 lumber
covered with fiberboard or any other type of sheathing, Stiff-bristle brush Angle grinder with
ask the veneer manufacturer for recommendations. Wide-mouth nippers diamond blade
Note: Installing from the top down makes cleanup or mason’s hammer Eye protection and
easier since it reduces the amount of splatter on Level work gloves
preceding courses. However, manufacturers advise Jointing tool
bottom-up installation for some veneers. Read the Veneer stones
manufacturer’s guidelines carefully before you begin. Veneer stone mortar or
Type S mortar mix
Mortar bag and
grout bag
Quick Tip ▸ Spray bottle
Whisk broom
Find the square footage of veneer stone required for
Expanded galvanized
your project by multiplying the length by the height of
metal lath
the area. Subtract the square footage of window and
(diamond mesh,
door openings and corner pieces. It’s best to increase
minimum 2.5#)
your estimate by 5 to 10 percent to allow for trimming.
A splash of manufactured veneer
stone, with its variations in color, tone
and shape, can set your home apart from
many of today’s cookie-cutter designs.256 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Finish Walls with Stone Veneer 1 2
Cover the wall with building paper, overlapping seams by Stake a level 2 × 4 against the foundation as a temporary
3 4”. Nail or staple lath every 6” into the wall studs and midway between studs. Nails or staples should penetrate 1” into the 4 ledger to keep the bottom edge of the veneer 4” above grade. The gap between the bottom course and the ground will studs. Paper and lath must extend at least 16” around corners reduce staining of the veneer by plants and soil. where veneer is installed.
3 4
Spread out the materials on the ground so you can select Mix a batch of veneer stone mortar that’s firm but still moist. pieces of varying size, shape, and color, and create contrast in Mortar that’s too dry or too wet is hard to work with and may the overall appearance. Alternate the use of large and small, fail to bond properly. heavily textured and smooth, and thick and thin pieces.
(continued)
Decorative Masonry Finishing ■ 257
5 6
Install corner pieces first, alternating long and short legs.
Dampen and apply mortar to the back of each piece, and
then press it firmly against the scratch coat so some mortar
squeezes out. Joints between stones should be no wider than
1
⁄2" and should remain as consistent as possible across the wall.
Quick Tip ▸
Use a square-end trowel to press a 3⁄8 to 1⁄2" layer of mortar Polymer-modified veneer stone mortar is
into the lath called the scratch coat. To ensure that mortar
recommended for drystack stone applications.
doesn’t set up too quickly, start with a 5-sq.-ft. area. Before the
mortar is set, use a brush or rake to roughen the surface. Allow Drystack stone is primarily bonded on one edge,
to set hard before moving onto the next step. Tip: Mix in small requiring twice the bond strength of regular mortar.
amounts of water to retemper mortar that has begun to thicken.
7 8
Set the first course of block into mortar, following the basic If mortar becomes smeared on a stone, remove it with a
techniques shown on pages 126 to 129. Cut blocks as needed whisk broom or soft-bristle brush after the mortar has begun
for the door openings. Lay the second course, offsetting the to dry. Never use a wire brush or a wet brush of any kind.
joints with the first course in a running-bond pattern.258 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
9 10
Use wide-mouth nippers or a mason’s hammer to trim and You can hide cut edges that are well above or below eye shape pieces to fit. Do your best to limit trimming so each level simply by rotating a stone. If an edge remains visible, piece retains its natural look. use mortar to cover. Let the mortar cure for 24 hours, and then remove the 2 × 4 and stakes, taking care not to dislodge any stones.
11 12
Once the wall is covered in veneer, fill in the joints using a Smooth the joints with a jointing tool once the mortar is mortar bag and tuck-pointing mortar. Take extra care to avoid firm. Once the mortar is dry to the touch, use a dry whisk smearing the mortar. You can tint the tuck-pointing mortar to broom to remove loose mortar—water or chemicals can leave complement the veneer. permanent stains.
Decorative Masonry Finishing ■ 259
■ Variation: Cast Veneer Stone
Cast veneer stones are thin synthetic masonry units that are applied to building walls to imitate the appearance of natural
stone veneer. They come in random shapes, sizes, and colors, but they are scaled to fit together neatly without looking unnaturally
uniform. Outside corner stones and a sill block (used for capping half-wall installations) are also shown here.
■ How to Install Cast Veneer Stone
1 2 3
Prepare the wall. Veneer stones Apply a scratch coat. The wall in the Test layouts. Uncrate large groups of
can be applied to a full wall or as an installation area should be covered with stones and dry-lay them on the ground
accent on the lower portion of a wall. a 1⁄2- to 3⁄4"-thick layer of mortar. Mix one to find units that blend well together in
A top height of 36 to 42" looks good. part Type N mortar to two parts masonry shape as well as in color. This will save
A layer of expanded metal lath (stucco sand and enough water to make the an enormous amount of time as you
lath) is attached over a substrate of consistency workable. Apply with a trowel, install the stones.
building paper. and let the mortar dry for 30 minutes.
Brush the surface with a stiff-bristle brush.260 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
4 5
Cut veneer stones, if necessary, by scoring with an angle Apply the stones. Mix mortar in the same ratios as in step grinder and diamond blade along a cutting line. Rap the waste 2, but instead of applying it to the wall, apply it to the backs of side of the cut near the scored line with a mason’s hammer or the stones with a trowel. A 1⁄2”-thick layer is about right. Press a maul. The stone should fracture along the line. the mortared stones against the wall in their position. Hold Try to keep the cut edge out of view as much as you can. them for a few second so they adhere.
6
L-bracketsFill the gaps between stones with mortar once all of the Option: Install sill blocks. These are heavier and wider than the stones are installed and the mortar has had time to dry. Fill a veneer block so they require some reinforcement. Attach three grout bag (sold at concrete supply stores) with mortar mixture 2 × 2” zinc-coated L-brackets to the wall for each piece of sill and squeeze it into the gaps. Once the mortar sets up, strike it block. Butter the backs of the sill blocks with mortar and press smooth with a jointing tool. them in place, resting on the L-brackets. Install metal flashing first for extra protection against water penetration.
Decorative Masonry Finishing ■ 261
Mortarless Brick Veneer Siding
A n interesting new siding product is now available
that mimics the appearance and durability of
classic brick, but that installs as easily as any other
siding material. Mortarless brick veneer systems use
stackable bricks to create an appealing façade on
wood, steel, or concrete structures. The high-strength
concrete bricks are long-lasting—manufacturers offer
warranties up to 50 years. And because brick veneer
does not require mortar, installation is well within the
capabilities of interested homeowners.
Veneer bricks are available in three and four inch
heights, and they are either eight or nine inches long,
depending on the producer. Bricks weigh approximately
five pounds each and add three and a quarter inches
to the face of walls. While veneer brick systems can be
used in both new construction and remodel projects,
application is restricted due to the added load: up to 30
feet high on standard wood framed walls. Consult with a Brick veneer siding attaches to your house with mechanical
professional builder or structural engineer for walls taller fasteners, so you can achieve the appeal of brick without the
than 30 feet, as well as sections of wall above roofs. mess of mortar.
When planning a brick veneer siding project, it’s
best to work with the manufacturer or a local dealer to
determine material availability in your area. To accurately The following pages discuss the installation of
estimate materials, you’ll need to know the total surface brick veneer siding on standard wood framed walls.
area to be covered with veneer brick, the width of each All openings require extra support in the form of
wall and opening for starter strip, and the length of each three-quarter-inch plywood lintels. Lintel size is
corner for quantity of corner strip and corner block. determined by the width of the opening and the
Prior to installation, make sure the framing and brick installation method over the opening (soldier
wall substrate is sound and the house is adequately coursing shown here). Contact the manufacturer
insulated. Extend all plumbing and electrical pipes, or product producer (see Resources, page 314)
boxes, and meters to accommodate the additional for information regarding lintel sizing, as well as
thickness created by the veneer brick and furring strips. installation of veneer brick on other framing styles.
Tools & Materials ▸
Tape measure Rubber mallet Furring strips Starter strips
Chalk line Cordless drill with Flashing Veneer bricks
4-ft. level various drivers Self-adhesive waterproof Outside corner blocks
Utility knife Caulk gun membrane (1 × 3, Inside corner blocks
Circular saw Eye protection 1 × 4, 1 × 6) Window sill block
Miter saw with diamond Work gloves #10 × 21⁄2" and #10 × 4" Construction adhesive
masonry-cutting blade Safety glasses corrosion-resistant Exterior-grade caulk
or wet masonry saw Dust mask wood screws
Hammer drill with Earplugs Scrap 2 × 4
masonry bits 3
⁄4" plywood Outside corner strips262 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Installing Brick Veneer Siding Brick veneer is stacked in courses with staggered Bricks are then fastened every fourth course joints, much like traditional brick. However, the thereafter. At outside corners, a specialty strip is first course of the mortarless system is installed on fastened to 1 × 4 furring strips. Corner blocks for a starter strip and fastened with corrosion-resistant both outside and inside corners are secured with screws to 1 × 3 furring strips at each stud location. screws and construction adhesive.
Before installing brick veneer siding, make sure all openings
are properly sealed. For best results, use a self-adhesive
waterproof membrane. Install the bottom strip first, and then the
side strips so they overlap the bottom strip. Place the top strip to
overlap the sides. Install drip-edge flashing where appropriate.Cut veneer brick using a miter saw with a diamond blade or Predrill holes in bricks that require fastening using a a wet masonry saw. When cutting brick, protect yourself with hammer drill with a 3⁄16” masonry bit. Position the brick face-up heavy work gloves, safety glasses, earplugs, and a dust mask. on the ground and secure with your foot. Drill through the See pages 116 to 117 for more brick cutting tips. notch in the top portion of the brick, holding the drill bit at 90° to the ground.
Decorative Masonry Finishing ■ 263
■ How to Install Mortarless Brick Veneer Siding
1 2
Snap a level chalk line 3⁄4" above the foundation on each For each opening, cut 3⁄4" plywood lintels to a size of 15" high ×
wall of the house. Align the bottom end of furring strips above 12" longer than the width of the opening. Center the lintel above
the chalk line. Fasten 1 × 3 furring strips at each stud location the opening so 6" extends beyond each side of the frame, and
with #10 × 21⁄2" corrosion-resistant wood screws. Install 1 × 4 fasten to framing with #10 screws. Install an aluminum drip-edge
furring strips at outside corners and 1 × 6s at inside corners. above the window frame, and then wrap the lintel and flashing
with a strip of self-adhesive waterproof membrane.
3 4
At outside corners, position the first section of corner strip Position the starter strip at the chalk line with the flange
2" above the chalk line. Plumb the strip using a 4-ft. level, and beneath the ends of the furring strips. Do not overlap corner
then fasten to the framing with #10 × 4" screws every 10" on strips. At inside corners, cut back the starter strip to so it falls
alternate sides. 31⁄2" short of adjacent walls. Level the strip, and then secure to
the framing with #10 × 4" corrosion-resistant wood screw at
each furring location.264 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
5 6
Predrill a hole at the notch in each corner block. Drill holes at Continue to install corner blocks using #10 × 21⁄2” screws a 30° angle using a hammer drill and a 3⁄16” masonry bit. Place and construction adhesive between courses. For the top of the a veneer brick on the starter strip for reference, and then slide corner, measure the remaining length and cut a piece of corner the first corner block down the corner strip and position it so strip to size. Fasten blocks to this loose length, cutting the final the bottom edge falls 1⁄2” below the bottom edge of the brick. piece to size if necessary (see page 189). Secure one last block Fasten the brick to the strip with #10 × 21⁄2” wood screws. to the existing corner using construction adhesive, and then fit the new assembly in place and fasten with #10 × 21⁄2” screws.
7 8
For inside corners, predrill holes at 30° angles into inside To create the best overall appearance, place a row of corner blocks. As with outside corners, position the first block bricks on the starter strip so they extend past the width of the so the bottom edge is 1⁄2” below the bottom edge of the first most prominent opening on each wall. Place a brick on the course of veneer brick. Fasten the block to the framing with second course at each end of the opening, so each sit evenly #10 × 4” wood screws. Continue installing blocks with #10 above the joint of two bricks below. Sight down from the edges screws and construction adhesive between each course. of the opening’s frame and adjust the entire row to find a pattern that yields the least amount of small pieces of brick around the opening.
(continued)
Decorative Masonry Finishing ■ 265
9 10
Predrill holes through veneer bricks for the first course (see At each furring strip, hold bricks flat against the wall and
page 265). Following the established pattern, install bricks on secure to the framing with #10 × 21⁄2" screws. Drive screws
starter strip. At corners, cut bricks to size, so they fit snugly until the head touches the brick. Do not over tighten.
against the blocks. Set bricks using a scrap 2 × 4 and rubber
mallet to help maintain consistent course alignment.
11 12
Fill the brick courses using bricks from different pallets to To install sill blocks below the widow, fasten a horizontal
blend slight variance in color. Set bricks using a scrap of 2 × 4 1 × 3 furring strip under the window frame, extending 1⁄8" longer
and a rubber mallet. Check every fourth course for level before than the cumulative width of the sill blocks. Install bricks up to
fastening bricks to the framing at each furring strip. the top of the furring strip, cutting to fit as needed, and fasten
each with two #10 × 21⁄2" wood screws. Apply construction
adhesive along the top of the furring strip and bricks.266 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
13 14
Install the sills, angling them downward slightly, and secure Continue installing brick along the openings, to a height no with #10 × 4” wood screws, toenailing through the ends or more than the width of one brick. Cut a piece of starter strip to bottom of the sill into the framing. Cut brick filler pieces to length, align it with the courses on either side of the opening, bridge the gap between the sill and the last full course of brick; and secure to the framing with #10 × 21⁄2” screws. Install a course make sure the pieces align with the rest of the course. Install of bricks on the starter strip, fastening them with #10 screws. the pieces with construction adhesive. Seal the gap between the window frame and the sill with exterior-grade caulk.
15 16
Cut bricks for the soldier course to length, and then install At the tops of walls, install 1 × 3 horizontal furring strips. vertically with two #10 × 21⁄2” screws each. For the final brick, Secure the second to the last course of bricks to the framing cut of the top portion and secure in place with construction with #10 × 21⁄2” screws, and then install the last course with adhesive. For a more symmetrical look, place cut bricks in the construction adhesive. Notch bricks to fit around joists or cut center of the course. at an angle for gable walls.
Decorative Masonry Finishing ■ 267
Tiling a Concrete Slab
O utdoor tile can be made of several different
materials and is available in many colors and
styles. A popular current trend is to use natural stone
Note: Wear eye protection when cutting tile and
handle cut tiles carefully—the cut edges of some
materials may be very sharp.
tiles with different shapes and complementary colors,
as demonstrated in this project. Tile manufacturers
may offer brochures giving you ideas for modular Tools & Materials ▸
patterns that can be created from their tiles. Make
sure the tiles you select are intended for outdoor use. Tape measure Paintbrush and roller
When laying a modular, geometric pattern with Pencil Plastic sheeting
tiles of different sizes, it’s crucial that you test the Chalk line Thinset mortar
layout before you begin and that you place the first Tile cutter or wet saw Modular tile
tiles very carefully. The first tiles will dictate the Tile nippers Grout
placement of all other tiles in your layout. Square-notched trowel Grout additive
You can pour a new masonry slab on which to 2 × 4 padded Grout sealer
install your tile patio, but another option is to finish with carpet Tile sealer
an existing slab by veneering it with tile—the scenario Hammer Eye protection and
demonstrated here. Grout float work gloves
Outdoor tile must be installed on a clean, flat, Grout sponge
and stable surface. When tiling an existing concrete Angle grinder
pad, the surface must be free of flaking, wide cracks, Caulk gun
and other major imperfections. A damaged slab can be Tile spacers
repaired by applying a one- to two-inch-thick layer of Buckets
new concrete over the old surface before laying tile.
Stone tiles can be laid as veneer over a concrete patio slab—a very easy way to create an elegant-looking patio.268 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Tile options for landscape installations:Slate Cut stone Terracotta tile Slate and other smooth, natural stone materials are durable and blend well with any landscape but are usually expensive. Quarry tile is less expensive, though only available in limited colors. Exterior-rated porcelain or ceramic tiles are moderately priced and available in a wide range of colors and textures, with many styles imitating the look of natural stone. Terra cotta tile is made from molded clay for use in warmer, drier climates only. Many of these materials require application of a sealer to increase durability and prevent staining and moisture penetration.
Quarry tile Ceramic tile
Tools for installing exterior tile include:
a wet saw for cutting tile quickly andAngle grinder Wet saw easily (available at rental centers—make certain to rent one that is big enough for the tile size you install), an angle grinder Sponge with a diamond-edged cutting blade (also a rental item) for cutting curves or other complex contours, a trowel with square notches (of the size required for your tile size) for spreading the mortar adhesive, spacers for accurate aligning of tiles and setting consistent joint widths, a straight length of 2 × 4 padded along one edge (carpet pad works well) for helping align tile surfaces, a grout float for spreading Notched trowel grout to fill the joints, and a sponge for cleaning excess grout from tile surfaces. Grout float Spacers Padded 2 × 4
Materials for installing exterior tile
Thinset mortar Grout Grout sealers include: latex-modified thinset mortar
adhesive that is mixed with water (if you
can’t find thinset that is latex modified,
buy unmodified thinset and mix it with
a latex additive for mortar, following
manufacturer’s directions), exterior-rated
grout available in a variety of colors to
match the tile you use, grout additive
to improve durability, grout sealer to
help protect grout from moisture and
staining, and tile sealer required for some
tile materials (follow tile manufacturer’s
requirements).
Grout additive
Decorative Masonry Finishing ■ 269
■ Tips for Evaluating Concrete Surfaces
A good surface is free from any major A fair surface may exhibit minor A poor surface contains deep or large
cracks or badly flaking concrete (called cracking and spalling but has no major cracks, broken, sunken, or heaved
spalling). You can apply patio tile directly cracks or badly deteriorated spots. Install concrete, or extensive spalling. If you have
over a concrete surface that is in good a new concrete sub base over a surface this kind of surface, remove the concrete
condition if it has control joints (see below). in fair condition before laying patio tile. completely and replace it with a new
concrete slab before you lay patio tile.
■ Tips for Cutting Control Joints in a Concrete Patio
Control joint
Control joint
location
Cut new control joints into existing concrete patios that are in good condition but do not have enough control joints. Control
joints allow inevitable cracking to occur in locations that don’t weaken the concrete or detract from its appearance. They should be
cut every 5 or 6 ft. in a patio. Plan the control joints so they will be below tile joints once the tile layout is established (photo, above
right). Use a circular saw with a masonry blade set to 3⁄8" depth to cut control joints. Cover the saw base with duct tape to prevent it
from being scratched.270 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Tile a Patio Slab House 1 Modular unit
Adjusted line
Center line
Adjusted lineTo establish a layout for tile with a modular pattern, you must carefully determine the location of the first tile. On the clean and dry concrete surface, measure and mark a center line down the center of the slab. Test-fit tiles along the line—because of the modular pattern used here, the tiles are staggered. Mark the edge of a tile nearest the center of the pad, and then create a second line perpendicular to the first and test-fit tiles along this line.
2
Make adjustments as needed so the modular pattern breaks evenly over the patio surface, and it is symmetrical from side to side. You may need to adjust the position of one or both lines. The intersection of the lines is where your tile installation will begin. Outline the position of each group of tiles on the slab.
Decorative Masonry Finishing ■ 271
3
Variation: To establish a traditional grid pattern, test-fit rows Following manufacturer’s instructions, mix enough
of tiles so they run in each direction, intersecting at the center thinset mortar to work for about 2 hours (start with 4 to 5"
of the patio. Adjust the layout to minimize tile cutting at the deep in a 5-gallon bucket). At the intersection of the two layout
sides and ends, and then mark the final layout and snap chalk lines, use a notched-edge trowel to spread thinset mortar over
lines across the patio to create four quadrants. As you lay tile, an area large enough to accommodate the layout of the first
work along the chalk lines and in one quadrant at a time. modular group of tiles. Hold the trowel at a 45° angle to rake
the mortar to a consistent depth.
4 5
Set the first tile, twisting it slightly as you push it into the Position the second tile adjacent to the first with a slight
mortar. Align it with both adjusted layout lines, and then place gap between them. Place spacers on end in the joint near each
a padded 2 × 4 over the center of the tile and give it a light rap corner and push the second tile against the spacers. Make
with a hammer to set the tile. certain the first tile remains aligned with the layout lines. Set the
padded 2 × 4 across both tiles and tap to set. Use a damp cloth
to remove any mortar that squeezes out of the joint or gets on
tile surfaces. Joints must be at least 1⁄8"-deep to hold grout.272 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
6 7
Lay the remaining tiles of the first modular unit using With the first modular unit set, continue laying tile spacers. Using the trowel, scrape the excess mortar from the following the pattern established. You can use the chalk lines concrete pad in areas you will not yet be working to prevent it for general reference, but they will not be necessary as layout from hardening and interfering with tile installation. lines. To prevent squeeze-out between tiles, scrape a heavy accumulation of mortar 1⁄2” away from the edge of a set tile before setting the adjacent tile.
Tips for Cutting Contours in Tile ▸
To make convex (above left) or concave (above right) curves, mark the profile of the curve on the tile, and then
use a wet saw to make parallel straight cuts, each time cutting as close to the marked line as possible. Use a tile nippers
to break off small portions of tabs, gradually working down to the curve profile. Finally, use an angle grinder to smooth
off the sharp edges of the tabs. Make sure to wear a particle mask when using the tile saw and wear sturdy gloves when
using the nippers.
Decorative Masonry Finishing ■ 273
8 9
After installing the tile, remove all the spacers, cover Use a grout float to spread grout over an area that is roughly
the tiled area with plastic, and let the thinset mortar cure 10 sq. ft. Push down with the face of the float to force grout
according to the manufacturer’s instructions. When tile has into the joints, and then hold the float edge at a 45° angle to
fully set, remove the plastic and mix grout using a grout the tile surfaces and scrape off the excess grout.
additive instead of water. Grout additive is especially important
in outdoor applications because it creates joints that are more
resilient in changing temperatures.
10
Once you’ve grouted this area, wipe off the grout residue using a damp sponge. Wipe with a light, circular motion—you want
to clean tile surfaces but not pull grout out of the joints. Don’t try to get the tile perfectly clean the first time. Wipe the area several
times, rinsing out the sponge frequently.274 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
11 Grouting Porous Tiles ▸ Some tiles, such as slate, have highly porous surfaces that can be badly stained by grout. For these tiles, apply grout by filling an empty caulk tube (available at tile stores and some building centers) with grout and apply the grout to the joints with a caulk gun. Cut the tip to make an opening just large enough to allow grout to be forced out. Run the tip down the joint between tiles as you squeeze out the grout. Remove the grout that gets on the tile surface with a wet sponge. You may need to use your finger to force grout into the joint—protect your skin by wearing a rubber glove.
Once the grout has begun to set (usually about 1 hour, depending on temperature and humidity), clean the tile surfaces again. You want to thoroughly clean grout residue from tile surfaces because it is difficult to remove once it has hardened. Buff off a light film left after final cleaning with a cloth.
12 13
Cover the patio slab with plastic and let the grout cure Apply tile sealer to the entire surface, using a paint roller. according to manufacturer’s instructions. Once the grout has Cover the patio with plastic and allow the sealer to dry cured, use a foam brush to apply grout sealer to only the grout, completely before exposing the patio to weather or traffic. wiping any spillover off of tile surfaces.
Decorative Masonry Finishing ■ 275
Tiling Concrete Steps Tools & Materials ▸
Pressure washer Paintbrush and roller
Masonry trowel Plastic sheeting
I n addition to the traditional tricks for improving your
home’s curb appeal—landscaping, fresh paint, pretty
windows—a tiled entry makes a wonderful, positive
4-ft. level
Carpenter’s square
Paper towels
Dry-set (thinset)
impression. To be suitable for tiling, stair treads Straightedge mortar
must be deep enough to walk on safely. Check local Tape measure Bonding adhesive
building codes for specifics, but most require that Chalk line Field tile
treads be at least eleven inches deep (from front to Tile cutter or wet saw Bullnose tile
back) after the tile is added. Tile nippers Grout
Before you start laying any tiles, the concrete Square-notched Grout additive
must be free of curing agents, clean, and in good trowel Latex tile caulk
shape. Make necessary repairs and give them time to Needle-nose plier Grout sealer
cure. An isolation membrane can be applied before Rubber mallet Tile sealer
the tile. This membrane can be a fiberglass sheet or Grout float 2×4
it can be brushed on as a liquid to dry. In either case, Grout sponge Carpet scrap
it separates the tile from the concrete, which allows Caulk gun Cold chisel or
the two to move independently and protects the tile Latex or epoxy flathead
from potential settling or shifting of the concrete. patching screwdriver
Choose exterior-rated, unglazed floor tile with a skid- compound Wire brush
resistant surface. Tile for the walking surfaces should Isolation membrane Broom
be at least one-half-inch thick. Use bullnose tiles at the Wet/dry vacuum Eye protection and
front edges of treads (as you would on a countertop) and Tile spacers work gloves
use cove tiles as the bottom course on risers. Buckets
Tiled front steps dramatically upgrade tired-looking, plain concrete. If your concrete is in good condition but you’re ready to add
curb appeal, this is a perfect DIY solution.276 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Tile Concrete Steps 1 2
Use a pressure washer to clean the surface of the concrete. Dig out rubble in large cracks and chips using a small cold Use a washer with at least 4,000 psi and follow manufacturer’s chisel or flathead screwdriver. Use a wire brush to loosen dirt instructions carefully to avoid damaging the concrete with the and debris in small cracks. Sweep the area or use a wet/dry pressurized spray. vacuum to remove all debris.
3 4 5
Fill small cracks and chips with If damage is located at a front Test the surface of the steps and masonry patching compound, using edge, clean it as described above. Place stoop for low spots, using a 4-ft. level a masonry trowel. Allow the patching a board in front and block the board in or other straightedge. Fill any low spots compound to cure according to place with bricks or concrete blocks. with patching compound and allow the manufacturer’s directions. Wet the damaged area and fill it with compound to cure thoroughly. patching compound. Use a masonry trowel to smooth the patch and then allow it to cure thoroughly.
(continued)
Decorative Masonry Finishing ■ 277
6 7
Spread a layer of isolation membrane over the concrete The sequence is important when tiling a stairway with
using a notched trowel. Smooth the surface of the membrane, landing. The primary objective is to install the tile in such a way
using the flat edge of a trowel. Allow the membrane to cure that the fewest possible cut edges are visible from the main
according to manufacturer’s directions. viewing position. If you are tiling the sides of concrete steps,
start laying tile there first. Begin by extending horizontal lines
from the tops of the stair treads back to the house on the sides
of the steps. Use a 4-ft. level.
8 9 10
Mix a batch of thinset mortar with Begin setting tiles into the thinset Wrap a 2 × 4 in old carpet and drag it
latex bonding adhesive and trowel mortar on the sides of the steps. Start at back and forth across the tile surfaces
it onto the sides of the steps, trying the top and work your way downward. Try to set them evenly. Don’t get too
to retain visibility of the layout lines. to lay out tile so the vertical gaps between aggressive here—you don’t want to
Because the top steps are likely more tiles align. Use spacers if necessary. dislodge all of the thinset mortar.
visible than the bottom steps, start on
top and work your way down.278 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
11 12
Measure the width of a riser, including the thickness of the Next, install the tiles on the stair risers. Because the tiles you’ve laid on the step sides. Calculate the centerpoint location of the tops of the riser tiles affects the positioning of and mark it clearly with chalk or a high visibility marker. the tread and landing tiles, you’ll get the most accurate layout if the riser tiles are laid first. Start by stacking tiles vertically against the riser. In some cases, you’ll only need one tile to reach from tread to tread. Add spacers. Trace the location of the tread across the back of the top tile to mark it for cutting.
13 14 15
Cut enough tiles to size to lay tiles Trowel thinset mortar mixed with Lay tiles on the risers. The bottom for all the stair risers. Be sure to allow bonding adhesive onto the faces of the tile edges can rest on the tread, and the enough space for grout joints if you are risers. In most cases, you should be able tops of the top tiles should be flush with stacking tiles. to tile each riser all at once. or slightly lower than the plane of the tread above.
(continued)
Decorative Masonry Finishing ■ 279
16 17
Dry-lay tile in both directions on the stair landing. You’ll Cut tiles as indicated by your dry run and begin installing
want to maintain the same grout lines that are established them by troweling thinset adhesive for the bullnose tiles at
by the riser tiles, but you’ll want to evaluate the front-to-back the front edge of the landing. The tiles should overlap the top
layout to make sure you don’t end up with a row of tiles that is edges of the riser tiles, but not extend past their faces.
less than 2" or so in thickness.
18 19
Field tile
Bullnose tile
Set the first row of field tiles, maintaining an even gap Add the last row of tiles next to the house and threshold,
between the field tiles and the bullnose tiles. cutting them as needed so they are between 1⁄4 and 1⁄2" away
from the house.280 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
20 21
Install tiles on the stair treads, starting at the top tread and Fill in the field tiles on the stair treads, being sure to leave a working your way downward. Set a bullnose tile on each side gap between the back tiles and the riser tiles that’s the same of the center line and work your way toward the sides, making thickness as the other tile gaps. sure to conceal the step side tiles with the tread tiles.
22 23 24
Let the thinset mortar cure for a few After a few weeks, seal the grout Select (or have prepared) a days, and then apply grout in the gaps lines with an exterior-rated grout sealer. pretinted caulk that’s the same color between tiles using a grout float. Wipe as your grout. Fill the gap between away the grout after it clouds over. In the back row of tiles and the house the event of rain, cover with plastic. with caulk. Smooth with a wet finger if needed.
Decorative Masonry Finishing ■ 281Repair & Maintenance C oncrete, brick, and stucco are among the world’s most durable and low-maintenance building materials, but they may need occasional upkeep and repairs to look and perform their best. Because masonry is very rigid (and sometimes because neighboring elements like wood and soil are not), cracking is one of the most common forms of damage. However, unless there’s a problem with the underlying soil or gravel base, most cracks have little or no effect on the slab’s performance, and repairs are often long-lasting.
In this chapter: • Repairing Concrete • Patcing Cracks • Quick Fixes for Wet Walls • Renewing an Old Concrete Slab • Repairing Steps • Miscellaneous Concrete Repairs • Brick Repairs • Repairing & Replacing Chimney Caps • Repairing Stonework • Repairing Stucco • Pressure-washing Masonry
■ 283
Repairing Concrete
L arge and small holes are treated differently when
repairing concrete. The best product for filling
in smaller holes (less than one half inch deep) is
vinyl-reinforced concrete patcher. Reinforced repair
products should be applied only in layers that are one
quarter inch thick or less. For deeper holes, use sand-
mix concrete with an acrylic fortifier, which can be
applied in layers up to two inches thick.
Patches in concrete will be more effective if you
create clean, backward-angled cuts around the damaged Tools & Materials ▸
area, to create a stronger bond. For extensive cutting of
damaged concrete, it’s best to score the concrete first
Trowels Vegetable oil or
with a circular saw equipped with a masonry blade. Use
Drill with masonry- commercial
a chisel and maul to complete the job.
grinding disc release agent
Circular saw with Hydraulic cement
masonry-cutting Bonding agent
blade Vinyl-reinforced
Tool Tip ▸ Cold chisel patching compound
Hand maul Sand-mix concrete
Use fast-set repair mortar or quick-setting cement Hose Concrete fortifier
with acrylic fortifier for repairing holes and chip-outs Paintbrush Plastic sheeting
in vertical surfaces. Because they set up in just a few Screed board Eye protection and
minutes, these products can be shaped to fill holes Float work gloves
without the need for forms. Scrap lumber
■ How to Patch a Small Hole
1 2
Cut out around the damaged area with a masonry-grinding Dampen the repair area with clean water and then fill it
disc mounted on a portable drill (or use a hammer and stone with vinyl concrete patcher. Pack the material in with a trowel,
chisel). The cuts should bevel about 15° away from the center allowing it to crown slightly above the surrounding surface.
of the damaged area. Chisel out any loose concrete within the Then, feather the edges so the repair is smooth and flat.
repair area. Always wear gloves and eye protection. Protect the repair from foot traffic for at least one day and
three days from vehicle traffic.284 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Patch a Large Hole 1
Use a hammer and chisel or a heavy floor scraper to OPTION: Make beveled cuts around the perimeter of the remove all material that is loose or shows any deterioration. repair area with a circular saw and masonry-cutting blade. The Thoroughly clean the area with a hose and nozzle or a bevels should slant down and away from the damage to create pressure washer. a “key” for the repair material.
2 3
Mix concrete patching compound according to the Smooth and feather the repair with a steel trowel so it is manufacturer’s instructions, and then trowel it neatly into the even with the surrounding concrete surface. Finish the surface damage area, which should be dampened before the patching of the repair material to blend with the existing surface. For material is placed. Overfill the damage area slightly. example, use a whisk broom to recreate a broomed finish. Protect the repair from foot traffic for at least one day and three days from vehicle traffic.
Repair & Maintenance ■ 285
Patching Cracks
T he materials and methods you should use for
repairing cracks in concrete depend on the location
and size of the crack. For small cracks (less than one
Tools & Materials ▸
half inch wide), you can use concrete repair caulk for Caulk gun Quick-setting
a quick aesthetic fix. Sanded acrylic repair caulks do a Cold chisel cement
good job of matching the color and texture of concrete Pointing trowel Acrylic fortifier
and stucco surfaces. Larger cracks require concrete Maul or hammer Hydraulic waterstop
repair materials that are fast-setting and high-strength Wire brush Vinyl concrete patcher
polymer modified compounds that significantly increase Fast-set repair and sand mix
the bonding properties and long-term durability of the mortar Polyurethane sealant
concrete repair. Cracks that are a result of continual slab
movement often cannot be repaired with a rigid concrete
repair material. These cracks should be repaired with
flexible polyurethane sealants that will elongate with the
movement of the flexible concrete crack.
Concrete repair caulk can be forced into small cracks to keep them from expanding. Smooth the caulk after application.
■ Recommended Crack Preparation
Best Acceptable Bad
The best way to repair cracks in concrete is to enlarge the crack first by chiseling a keyway along the crack path with a cold
chisel. The best holding power for the new patch material is achieved if you chisel in a dovetail shape. A square keyway will also
work. A V-shaped keyway will ultimately lead to failure of the repair.286 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Repair Horizontal Cracks 1 2
Prepare the crack for the repair materials by knocking Mix the repair product to fill the crack according to the away any loose or deteriorating material and beveling the manufacturer’s instructions. Here, a fast-setting cement repair edges down and outward with a cold chisel. Sweep or vacuum product with acrylic fortifier is being used. Trowel the product the debris and thoroughly dampen the repair area. Do not, into the crack, overfilling slightly. With the edge of the trowel, however, allow any water to pool. trim the excess material and feather it so it is smooth and the texture matches the surrounding surface.
■ How to Repair Vertical Cracks 1 2
Prepare the crack for repair as with a horizontal crack (step Shape or trim the concrete repair product so it is even with 1, above) and then fill the crack with fast-setting repair mortar. surrounding surface and the textures match. If the material The mixture should have a fairly dry consistency so it does not has set too much and is difficult to work, try using a wire run out of the crack. Overfill the crack slightly and allow the attachment on a power drill. repair material to set up.
Repair & Maintenance ■ 287
Quick Fixes for Wet Walls
F ailing gutters, broken or leaking pipes,
condensation, and seepage are the most common
causes of basement moisture. If allowed to persist,
damp conditions. Thinner brush-on coatings are also
available. For chronic seepage, ask a contractor to
install a baseboard gutter and drain system.
dampness can cause major damage to concrete Remember: To prevent long-term damage, it’s
basement walls. There are several effective ways to necessary to identify the source of the moisture and
seal and protect the walls. If condensation is the make repairs both inside and outside your home, so
source of the problem, check first that your clothes moisture no longer penetrates foundation walls.
dryer is properly vented, and install a dehumidifier. If
water is seeping in through small cracks or holes in
the walls, repair damaged gutters and leaky pipes, and Tools & Materials ▸
check the grade of the soil around your foundation.
Once you’ve addressed the problem at its source, Wire brush Hydraulic water
create a waterproof seal over openings in the basement Stiff-bristle stop cement
walls. To stop occasional seepage, coat the walls with paintbrush Heavy-duty
masonry sealer. For more frequent seepage, seal the Sponge masonry coating
openings and resurface the walls with a water-resistant Square-end trowel Surface bonding
masonry coating. Heavy-duty coatings, such as surface cement
bonding cement (opposite page), are best for very
Although most water problems in basements are not caused by cracks in the foundation wall, a large crack should be repaired
immediately, especially in a damp basement. To repair it, create a dovetail-shaped keyway with a cold chisel and maul, and then fill
the crack with hydraulic repair cement (this product actually cures and hardens when it contacts water).288 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Tips for Inspecting & Sealing Basement Walls ▸
Paint that is peeling off basement walls usually Tape a square of aluminum foil to a masonry wall to indicates water seepage from outside that is trapped identify high moisture levels. Check the foil after 24 hours. between the walls and the paint. Beads of water on top of the foil indicate high humidity in the room. Beads of water underneath suggest water seepage through the wall from outside.
To control minor seepage through porous concrete Resurface heavily cracked masonry walls with and masonry, seal walls with a cement-based masonry a water-resistant masonry coating, such as fiber- sealer. Clean the walls and prepare by adding acrylic reinforced surface bonding cement with acrylic fortifier. fortifier to heavy-duty masonry coating. Dampen the Clean and dampen the walls according to the coating walls and apply masonry coating to the walls (including manufacturer’s instructions, and then fill large cracks and all masonry joints) with a stiff masonry brush in a holes with the coating. Finally, plaster a 1⁄4” layer of the circular motion. coating on the walls using a finishing trowel. Specially formulated heavy-duty masonry coatings are available for very damp conditions.
Repair & Maintenance ■ 289
Renewing an Old Concrete Slab
O ver time, exposed concrete surfaces can start
to show a lot of wear. Weather, hard use, and
problems with the initial pour and finishing are among
For a smooth finish, spread the resurfacer with a
squeegee or trowel. For a textured or nonslip surface,
you can broom the surface before it dries or use a
the most common causes of surface blemishes. masonry brush for smaller applications.
But despite a shabby appearance, old concrete is
often structurally sound and can last for many more
years. So instead of breaking up and replacing an old Tools & Materials ▸
slab, you can easily renew its surface with concrete
resurfacer. With the simple application, your concrete 3,500 psi pressure 1
⁄2" drill with paddle
will have a freshly poured look and a protective surface washer mixer
layer that’s typically stronger than the slab itself. Steel concrete Duct tape or backer
Concrete resurfacer is suitable for any size finishing trowel rod
of slab, outdoors or indoors. You can also apply it Long-handled Stiff-bristle broom
to vertical surfaces to put a fresh face on steps, squeegee Concrete resurfacer
curbs, and exposed patio edges. Depending on the Concrete cleaner Eye protection and
condition of the old surface, the new layer can range 5-gal. bucket work gloves
in thickness from one sixteenth to one quarter inch.
After Before
Concrete resurfacer offers an easy, inexpensive solution for renewing patios, driveways, paths, steps, and other concrete
surfaces that have become chipped and flaked with age.290 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Renew an Old Slab 1 2
Thoroughly clean the entire project area. If necessary, Wash the concrete with a pressure washer. Set the remove all oil and greasy or waxy residue using a concrete washer at 3,500 psi, and hold the fan-spray tip about 3” from cleaner and scrub brush. Water beading on the surface the surface or as recommended by the washer manufacturer. indicates residue that could prevent proper adhesion with the Remove standing water. resurfacer; clean these areas again as needed.
3 4
Fill sizeable pits and spalled areas using a small batch On a large project, section off the slab into areas no larger of concrete resurfacer—mix about 5 pints of water per than 100 sq. ft. It’s easiest to delineate sections along existing 40-lb. bag of resurfacer for a trowelable consistency. Repair control joints. On all projects, cover or seal off all control cracks or broken slab edges as shown on pages 286 to 287. joints with duct tape, foam backer rod, or weatherstripping to Smooth the repairs level with the surrounding surface, and prevent resurfacer from spilling into the joints. let them harden.
(continued)
Repair & Maintenance ■ 291
5 6
Saturate the work area with water, and then use a squeegee to
remove any standing water. Pour the mix of concrete resurfacer
onto the center of the repair area or first repair section.
Tool Tip ▸
For improved color consistency, apply a thin, slurry
Mix the desired quantity of concrete resurfacer with water,
coat of concrete resurfacer to seal the concrete
following the mixing instructions. Work the mix with a 1⁄2"
drill and a mixing paddle for 5 minutes to achieve a smooth, substrate. An additional coat can be applied after
pourable consistency. If necessary, add water sparingly until two hours.
the mix will pour easily and spread well with a squeegee.
7
Spread the resurfacer with the squeegee using a scrubbing motion to make sure all depressions are filled. Then, spread it
into a smooth, consistent layer. If desired, broom the surface for a nonslip finish (opposite page). You can also tool the slab edges
with a concrete edger within 20 minutes of application. Let the resurfacer cure. Resurface outdoor projects when the temperature
will stay above 50°F for 8 hours and the surface won’t freeze for at least 24 hours. Cover the area only if necessary to protect it
from rain in the first 6 hours of curing (this may affect surface appearance and uniformity). During extreme wind or sun conditions,
moist-cure the surface with a water fog-spray twice daily for 24 to 48 hours after application. Let resurfacer cure for 6 hours before
allowing foot traffic and 24 hours before vehicle traffic (wait longer during cold weather).292 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Options for Resurfacer Finishes ▸
For thicker resurfacing, simply add more layers of Nonslip broomed finish: Within 5 minutes of applying resurfacer as needed. Wait until the surface can support the resurfacer, drag a clean fine-bristled push broom foot traffic—typically 2 to 6 hours—before applying the across the surface. Pull the broom backward in a straight next coat. line, moving across the entire area without stopping. Repeat in parallel rows until the entire surface is textured.
Trowel application: A trowel is handy for resurfacing Brush application: Resurface curbs, step risers, and slab small areas. Use a stiffer mix for troweling—approximately 5 edges using a masonry brush. Mix a workably stiff batch pints of water per 40-lb. bag of dry mix. Spread and smooth of resurfacer, and apply it evenly over the repair area. the resurfacer with a steel concrete finishing trowel. Finishing the surface with short brush strokes produce a mottled appearance; straight, continuous strokes create a broomed look.
Repair & Maintenance ■ 293
Repairing Steps
S teps require more maintenance and repair than
other concrete structures around the house
because heavy use makes them more susceptible to
damage. Horizontal surfaces on steps can be treated
using the same products and techniques used on other
masonry surfaces. For vertical surfaces, use quick-
setting cement, and shape it to fit.
Tools & Materials ▸
Trowel Vegetable oil or
Wire brush commercial
Paintbrush release agent
Circular saw with Latex bonding agent
masonry-cutting Vinyl-reinforced
blade patching
Chisel compound
Float Quick-setting
Edger cement Damaged concrete steps are an unsightly and unsafe way
Scrap lumber Plastic sheeting to welcome visitors to your home. Repairing cracks as they
Eye protection Work gloves develop not only keeps the steps in a safer and better looking
condition, but also prolongs their life.
■ How to Patch a Corner
Clean chipped concrete with a wire Mix patching compound with Tape scrap lumber pieces around
brush. Brush the patch area with latex latex bonding agent, as directed by the patch as a form. Coat the insides
bonding agent. the manufacturer. Apply the mixture with vegetable oil or commercial release
to the patch area, and then smooth agent so the patch won’t adhere to the
the surfaces and round the edges, as wood. Remove the wood when the patch
necessary, using a flexible knife or trowel. is firm. Cover with plastic and protect
from traffic for at least one week.294 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Patch Step Treads 1 2
Riser
TreadMake a cut in the stair tread just outside the damaged area Cut a form board the same height as the step riser. Coat using a circular saw with a masonry-cutting blade. Make the one side of the board with vegetable oil or commercial release cut so it angles toward the back of the step. Make a horizontal agent to prevent it from bonding with the repair, and then cut on the riser below the damaged area, and then chisel out press it against the riser of the damaged step. Brace it in the area in between the two cuts. position with heavy blocks. Make sure the top of the form is flush with the top of the step tread.
3 4
Apply latex bonding agent to the repair area with a clean Smooth the concrete with a float, and let it set for a few paintbrush, wait until the bonding agent is tacky (no more than minutes. Round over the front edge of the nose with an edger. 30 min.), and then press a stiff mixture of quick-setting cement Use a trowel to slice off the sides of the patch, so it is flush into the damaged area with a trowel. with the side of the steps. Cover the repair with plastic and wait a week before allowing traffic on the repaired section.
Repair & Maintenance ■ 295
Miscellaneous Concrete Repairs
T here are plenty of concrete problems you may
encounter around your house that are not specifically
addressed in many repair manuals. These miscellaneous
repairs include such tasks as patching contoured objects
that have been damaged and repairing masonry veneer
around the foundation of your house. You can adapt
basic techniques to make just about any type of concrete
repair. Remember to dampen concrete surfaces before
patching so that the moisture from concrete and other
patching compounds is not absorbed into the existing
surface. Be sure to follow the manufacturer’s directions
for the repair products you use.
Tools & Materials ▸
Putty knife Soft-bristle brush
Trowel Emery paper
Hand maul Wire lath
Chisel Masonry anchors
Wire brush Concrete acrylic
Aviation snips fortifier
Concrete slabs that slant toward the house can lead to
Drill Sand-mix foundation damage and a wet basement. Even a level slab near
Quick-setting Eye protection and the foundation can cause problems. Consider asking a concrete
cement work gloves contractor to fix it by mud-jacking, forcing wet concrete
underneath the slab to lift the edge near the foundation.
■ How to Repair Shaped Concrete
1 2
Scrape all loose material and debris from the damaged Use the trowel or a putty knife to mold the concrete to follow
area, and then wipe down with water. Mix quick-setting the form of the object being repaired. Smooth the concrete as
cement and trowel it into the area. Work quickly—you only soon as it sets up. Buff with emery paper to smooth out any
have a few minutes before concrete sets up. ridges after the repair dries.296 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Repair Masonry Veneer 1 2 Old metal lath
New metal lathChip off the crumbled, loose, or deteriorated veneer from Clean up any metal lath in the repair area if it is in good the wall using a cold chisel and maul. Chisel away damaged condition. If not, cut it out with aviation snips. Add new lath veneer until you have only good, solid surface remaining. Use where needed using masonry anchors to hold it to the wall. care to avoid damaging the wall behind the veneer. Clean the repair area with a wire brush.
3 4
Mix fortified sand-mix concrete (or specialty concrete Re-create the surface texture to match the surrounding blends for wall repair) and trowel it over the lath until it is even area. For our project, we used a soft-bristled brush to stipple with the surrounding surfaces. the surface. To blend in the repair, add pigment to the sand mixture or paint the repair area after it dries.
Repair & Maintenance ■ 297
Brick Repairs Tools & Materials ▸
Raking tool Gravel
Mortar hawk Scrap of metal flashing
T he most common brick wall repair is tuck-pointing,
which is the process of replacing failed mortar
joints with fresh mortar. Tuck-pointing is a highly
Tuck-pointer
Jointing tool
Replacement bricks
or blocks
useful repair skill for any homeowner to possess. It Bricklayer’s hammer Mortar repair caulk
can be used to repair walls, chimneys, brick veneer, Mason’s trowel Eye protection and
or any other structure where the bricks or blocks are Mason’s or work gloves
bonded with mortar. stone chisel
Minor cosmetic repairs can be attempted on any Hammer
type of wall, from freestanding garden walls to block Drill with masonry
foundations. Filling minor cracks with caulk or repair disc and bit
compound and patching popouts or chips are good Pointing trowel
examples of minor repairs. Consult a professional Stiff-bristle brush
before attempting any major repairs like replacing Mortar (Type S or N)
brick or blocks, or rebuilding a structure—especially if
you are dealing with a load-bearing structure.
Making Repairs Blend ▸
Add mortar tint to your mortar mix to help repairs
blend in. Fresh mortar usually stands out because it
is too light. For some repairs, you can use pre-tinted
mortar repair caulk.
Make timely repairs to brick and block structures. Tuck-
pointing deteriorated mortar joints is a common repair that,
like other types of repair, improves the appearance of the
structure or surface and helps prevent further damage.298 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Replace Deteriorated Mortar Joints 1 2 Tuck-pointer
Mortar hawkClean out loose or deteriorated mortar to a depth of 1⁄4 to Mix the mortar to a firm workable consistency; add tint if 3 ⁄4”. Use a mortar raking tool (top) first, and then switch to necessary. Load mortar onto a mortar hawk, and then push it a masonry chisel and a hammer (bottom) if the mortar is into the horizontal joints with a tuck-pointer. Apply mortar in 1⁄4- stubborn. Clear away all loose debris, and dampen the surface to 1⁄2”-thick layers, and let each layer dry for 30 minutes before with water before applying fresh mortar. applying another. Fill the joints until the mortar is flush with the face of the brick or block.
3 4After the final layer of mortar is applied, smooth the joints with Apply mortar repair caulk with firm pressure filling the a jointing tool that matches the profile of the old mortar joints. Tool mortar joint from back to front in multiple layers. Use the the horizontal joints first. Let the mortar dry until it is crumbly, and square applicator tip or a jointing tool to smooth the joint. then brush off the excess mortar with a stiff-bristle brush.
(continued)
Repair & Maintenance ■ 299
■ How to Replace a Damaged Brick
1 2
Score the damaged brick so it will break apart more easily Use a mason’s chisel and hammer to break apart the
for removal. Use a drill with a masonry-cutting disc to score damaged brick along the scored lines. Rap sharply on
lines along the surface of the brick and in the mortar joints the chisel with the hammer, being careful not to damage
surrounding the brick. surrounding bricks. Tip: Save fragments to use as a color
reference when you shop for replacement bricks.
3 4
Chisel out any remaining mortar in the cavity, and then Mix the mortar for the repair and tint if needed to match
brush out debris with a stiff-bristle or wire brush to create old mortar. Use a pointing trowel to apply a 1"-thick layer of
a clean surface for the new mortar. Rinse the surface of the mortar at the bottom and sides of the cavity.
repair area with water.300 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
5 6
Dampen the replacement brick slightly, then apply mortar Scrape away excess mortar with a masonry trowel, and to the ends and top of the brick. Fit the brick into the cavity then smooth the joints with a jointing tool that matches the and rap it with the handle of the trowel until the face is flush profile of the surrounding mortar joints. Let the mortar set until with the surrounding bricks. If needed, press additional mortar crumbly, and then brush the joints to remove excess mortar. into the joints with a pointing trowel.
Tips for Removing & Replacing Several Bricks ▸
For walls with extensive damage, remove bricks from For walls with internal damaged areas, remove only
the top down, one row at a time, until the entire damaged the damaged section, keeping the upper layers intact
area is removed. Replace bricks using the techniques if they are in good condition. Do not remove more than
shown above and in the section on building with brick four adjacent bricks in one area—if the damaged area is
and block. Caution: Do not dismantle load-bearing brick larger, it will require temporary support, which is a job for
structures like foundation walls—consult a professional a professional mason.
mason for these repairs.
Repair & Maintenance ■ 301
Repairing & Replacing Chimney Caps
C himney caps undergo stress because the
temperatures of the cap and chimney flue
fluctuate dramatically. Use fire-rated silicone caulk
Floating chimney
cap (shown cutaway,
with form in place for
illustration purposes)
to patch minor cracks. For more extensive repairs,
reapply fresh mortar over the cap, or replace the old
cap for a permanent solution. Shown cutaway
Flue
2" overhang
Tools & Materials ▸ 3 ⁄ 2"
1
4 3⁄ 4" (all sides)
Hammer Plywood (1⁄2, 3⁄4") 1
⁄ 2" plywood
Stone chisel 3
⁄8" dowel 3
⁄4" plywood
Wire brush 11⁄2" wood screws
Drill Vegetable oil or
Float a commercial
Pointing trowel release agent
Tape measure Fire-rated silicone A chimney cap expands and shrinks as temperatures
change inside and outside the chimney. This often results in
Caulk gun caulk
cracking and annual treks up to the roof for repairs. A floating
Latex-fortified Fire-rated rope or chimney cap (above) is cast in a form using mortar or sand-mix
mortar mineral wool concrete, and then placed on the top of the chimney (opposite
Concrete fortifier Work gloves page). You can repair a damaged cap by chipping off the
deteriorated sections and adding fresh mortar (below).
■ How to Repair a Chimney Cap
1 2
Carefully break apart and remove the deteriorated sections Mix a batch of latex-fortified mortar. Trowel an even layer
of the chimney cap using a stone chisel and hammer. of mortar all the way around the chimney cap, following the
slope of the existing cap. Mortar should cover the chimney
from the outside edges of the chimney bricks to the flue.
Smooth out the mortar with a wood float, trying to recreate the
original slope of the chimney cap. Inspect the mortar annually.302 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Cast & Install a Replacement Chimney Cap 1 2
Measure the chimney and the chimney flue and build a Prepare a stiff (dry) mixture of mortar to cast the cap—for form from 1⁄2 and 3⁄4” plywood (form dimensions on opposite average-sized chimneys, two 60-lb. bags of dry mix should page, top). Attach the form to a plywood base using 11⁄2” wood yield enough mortar. Fill the form with mortar. Rest a wood screws. Glue 3⁄8” dowels to the base, 1” inside the form. The float across the edges of the form and smooth the mortar. dowels will cast a drip edge into the cap. Coat the inside of the Keep angles sharp at the corners. Let the cap cure for at least form with vegetable oil or a commercial release agent. a week, and then carefully disassemble the form.
3 4
Chip off the old mortar cap completely, and clean the top Shift the cap so the gap next to the flue is even on all sides, of the chimney with a wire brush. With a helper, transport the and then fill in the gap with fire-rated rope or mineral wool. chimney cap onto the roof and set it directly onto the chimney, Caulk over the fill material with a very heavy bead of fire-rated centered so the overhang is equal on all sides. For the new cap silicone caulk. Also caulk the joint at the underside of the cap. to function properly, do not bond it to the chimney or the flue. Inspect caulk every other year and refresh as needed.
Repair & Maintenance ■ 303
Repairing Stonework
D amage to stonework is typically caused by frost
heave, erosion or deterioration of mortar, or by
stones that have worked out of place. Dry-stone walls
are more susceptible to erosion and popping while
mortared walls develop cracks that admit water, which
can freeze and cause further damage.
Inspect stone structures once a year for signs of
damage and deterioration. Replacing a stone or repointing
crumbling mortar now will save you work in the long run.
A leaning stone column or wall probably suffers
from erosion or foundation problems and can be
dangerous if neglected. If you have the time, you can
tear down and rebuild dry-laid structures, but mortared
structures with excessive lean need professional help.
Tools & Materials ▸
Maul Masonry chisels
Chisel Wood shims
Camera Carpet-covered
Shovel 2×4
Hand tamper Chalk
Level Compactable gravel
Batter gauge Replacement stones
Stiff-bristle brush Type M mortar
Trowels for mixing Mortar tint
and pointing Eye protection and Stones in a wall can become dislodged due to soil settling,
Mortar bag work gloves erosion, or seasonal freeze-thaw cycles. Make the necessary
repairs before the problem migrates to other areas.
Tips for Repairing Popped Stones ▸
Return a popped stone to its original position. If other Use a 2 × 4 covered with carpet to avoid damaging the
stones have settled in its place, drive shims between stone when hammering it into place. After hammering,
neighboring stones to make room for the popped stone. make sure a replacement stone hasn’t damaged or
Be careful not to wedge too far. dislodged the adjoining stones.304 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Rebuild a Dry-stone Wall Section 1 2
Study the wall and determine how much of it needs to be Capstones are often set in a mortar bed atop the last rebuilt. Plan to dismantle the wall in a V shape, centered on the course of stone. You may need to chip out the mortar with a damaged section. Number each stone and mark its orientation maul and chisel to remove the capstones. Remove the marked with chalk so you can rebuild it following the original design. stones, taking care to check the overall stability of the wall as Tip: Photograph the wall, making sure the markings are visible. you work.
3 Tip for Erosion ▸
Rebuild the wall, one course at a time, using replacement stones only when necessary. Start each course at the ends and If you’re rebuilding because of erosion, dig a work toward the center. On thick walls, set the face stones first, trench at least 6” deep under the damaged area, and and then fill in the center with smaller stones. Check your work fill it with compactable gravel. Tamp the gravel with a with a level and use a batter gauge to maintain the batter of hand tamper. This will improve drainage and prevent the wall. If your capstones were mortared, re-lay them in fresh water from washing soil out from beneath the wall. mortar. Wash off the chalk with water and a stiff-bristle brush.
Repair & Maintenance ■ 305
■ Tips for Repairing Mortared Stone Walls
1 2
Tint mortar for repair work so it blends with the existing Use a mortar bag to restore weathered and damaged mortar
mortar. Mix several samples of mortar, adding a different joints over an entire structure. Remove loose mortar (see
amount of tint to each and allow them to dry thoroughly. below) and clean all surfaces with a stiff-bristle brush and
Compare each sample to the old mortar and choose the water. Dampen the joints before tuck-pointing and cover all of
closest match. the joints, smoothing and brushing as necessary.
■ How to Repoint Mortar Joints
1 2
Carefully rake out cracked and crumbling mortar, stopping Mix Type M mortar, and then dampen the repair surfaces
when you reach solid mortar. Remove loose mortar and debris with clean water. Working from the top down, pack mortar into
with a stiff-bristle brush. Tip: Rake the joints with a chisel the crevices using a pointing trowel. Smooth the mortar when
and maul or make your own raking tool by placing an old it has set up enough to resist light finger pressure. Remove
screwdriver in a vice and bending the shaft about 45º. excess mortar with a stiff-bristle brush.306 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Replace a Mortared Stone Wall 1 2
Remove the damaged stone by chiseling out the surrounding Brush out the cavity to remove loose mortar and debris. Test mortar using a masonry chisel or a modified screwdriver the surrounding mortar and chisel or scrape out any mortar (opposite page). Drive the chisel toward the damaged stone that isn’t firmly bonded. to avoid harming neighboring stones. Once the stone is out, chisel the surfaces inside the cavity as smooth as possible.
3 4
Dry-fit the replacement stone. The stone should be stable Mist the stone and cavity lightly, and then apply Type M in the cavity and blend with the rest of the wall. You can mark mortar around the inside of the cavity using a trowel. Butter the stone with chalk and cut it to fit (page 179), but excessive all mating sides of the replacement stone. Insert the stone and cutting will result in a conspicuous repair. wiggle it forcefully to remove any air pockets. Use a pointing trowel to pack the mortar solidly around the stone. Smooth the mortar when it has set up.
Repair & Maintenance ■ 307
Repairing Stucco
A lthough stucco siding is very durable, it can be
damaged and over time it can crumble or crack.
The directions given below work well for patching
small areas less than two square feet. For more
extensive damage, the repair is done in layers, as
shown on the opposite page.
Fill thin cracks in stucco walls with a sanded
acyrlic stucco caulk. Overfill the crack with caulk and
feather until it’s flush with the stucco. Allow the caulk
to set, and then paint it to match the stucco. Masonry
caulk stays semiflexible, preventing further cracking.
Premixed stucco patch works well for small holes,
cracks, or surface defects. Repairs to large damaged
areas often require the application of multiple layers
of base coat stucco and a finish coat stucco. Matching
the stucco texture may require some practice.
Tools & Materials ▸
Caulk gun Steel trowel
Wire brush Stucco repair products
Putty knife Building paper
Whisk broom Stucco lath
Hammer Roofing nails
Fill thin cracks in stucco walls with stucco repair caulk.
Masonry chisel Work gloves, eye Overfill the crack with caulk and feather until it’s flush
Drill with masonry bit protection, and with the stucco. Allow the caulk to set and then paint it to
Pointing trowel particle mask match the stucco. Stucco caulk stays semiflexible, preventing
further cracking.
■ How to Patch Small Areas
1 2 3
Remove loose material from the Apply premixed stucco patch Smooth the repair with a putty knife
repair area using a wire brush. Use compound to the repair area, slightly or trowel, feathering the edges to blend
the brush to clean away rust from any overfilling the hole using a putty knife into the surrounding surface. Use a whisk
exposed metal lath, and then apply a or trowel. broom or trowel to duplicate the original
coat of metal primer to the lath. texture. Let the patch dry for several days,
and then touch it up with masonry paint.308 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ How to Patch Large Areas 1 2
Make a starter hole with a drill and masonry bit, and then Apply a 3⁄8”-thick layer of base coat stucco directly to the use a masonry chisel and hammer to chip away stucco in the metal lath. Push the stucco into the mesh until it fills the repair area. Cut self-furring metal lath to size and attach it to gap between the mesh and the sheathing. Score horizontal the sheathing using roofing nails. Overlap pieces by 2”. If the grooves into the wet surface using a scratching tool. Let the patch extends to the base of the wall, attach a metal stop bead stucco cure for up to two days, misting it with water every 2 to at the bottom. Note: Wear safety glasses and a particle mask or 4 hours. respirator when cutting stucco.
3 4
Apply a second, smooth layer of stucco after the first Combine finish coat stucco mix with just enough water for coat has become sufficiently firm to hold the second coat the mixture to hold its shape. Dampen the patch area, and then without sagging. Build up the stucco to within 1⁄4” of the original apply the finish coat to match the original surface. Dampen the surface. Let the patch cure for up to two days, misting every 2 patch occasionally. Let it cure for 7 days before painting with to 4 hours. acrylic or water-based paint and 28 days for oil-based.
Repair & Maintenance ■ 309
Pressure-washing Masonry
A typical residential-grade pressure washer can be as
much as 50 times more powerful than a standard
garden hose, while using up to 80 percent less water.
nozzle and the surface—move the nozzle back to reduce
the pressure; move the nozzle closer to intensify it.
To successfully clean any masonry or stone
A pressure washer comprises an engine to generate surface using a pressure washer, follow these tips:
power, a pump to force water supplied from a garden
hose through a high-pressure hose, and a nozzle to • When cleaning a new surface, start in an incon-
accelerate the water stream leaving the system. This spicuous area, with a wide spray pattern and the
results in a high-pressure water jet ranging from 500 to nozzle four to five feet from the surface. Move closer
4,000 pounds per square inch (PSI). to the surface until the desired effect is achieved.
A pressure washer’s cleaning power is noted in • Keep the nozzle in constant motion, spraying at
gallons per minute (GPM) to rinse away loosened dirt a steady speed with long, even strokes to ensure
and grime from the area; a pressure washer with a higher consistent results.
GPM cleans faster than a lower-flow unit. For general • Maintain a consistent distance between the nozzle
cleaning around your outdoor home, a pressure washer and the cleaning surface.
around 2,500 PSI and 2.5 GPM is more than sufficient. • When cleaning heavily soiled or stained surfaces,
Pressure washing is quite simple: Firmly grasp the use cleaning detergents formulated for pressure
spray wand with both hands, depress the trigger, and move washers. Always rinse the surface before
the nozzle across the surface to be cleaned. Although applying the detergent. On vertical surfaces,
different surfaces require different spray patterns and apply detergent from bottom to top, and rinse
pressure settings, it is not difficult to determine the from top to bottom. Always follow the detergent
appropriate cleaning approach for each project. The nozzle manufacturer’s directions.
is adjustable—from a low-pressure, wide-fan spray for • After pressure washing, always seal the surface
general cleaning and rinsing, to a narrow, intense stream with an appropriate surface sealer (e.g., concrete
for stubborn stains. But the easiest way to control the sealer for cement driveways), following the
cleaning is to simply adjust the distance between the product manufacturer’s instructions.
Pressure Washer Safety ▸
• Always wear eye protection.
• Wear shoes, but not open-toed shoes.
• Make sure the unit is on a stable surface and the
cleaning area has adequate slopes and drainage
to prevent puddles.
• Assume a solid stance and firmly grasp the
spray gun with both hands to avoid injury if the
gun kicks back.
• Always keep the high-pressure hose connected
to both the pump and the spray gun while the
system is pressurized.
• Never aim the nozzle at people or animals—
the high-pressure stream of water can cause
serious injury.
To clean the masonry and stonework surfaces around the
outside of your home, there is nothing that works faster or
more effectively than a pressure washer.310 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
■ Pressure-washing Masonry & Stonework 1 2
Eve
ns
tea
dy
pat
hAlways keep the nozzle in motion, spraying at a steady Hold the spray wand so that the nozzle distributes the speed and using long, even strokes. Take multiple passes spray pattern across the surface evenly. Holding the nozzle over heavily soiled areas. Take care not to dwell on one spot at too low an angle can cause an uneven spray pattern, for too long, especially when using narrow, high-pressure resulting in “zebra striping.” Also, maintain a consistent spray patterns. distance between the nozzle and the cleaning surface to ensure consistent results and help flush dirt and debris from the area.
3 4
Work in identifiable sections, such as the area between the To prevent streaks on vertical surfaces, always begin expansion joints in concrete. If there is a slope, work downhill pressure washing or applying cleaning detergent at the bottom to promote drainage and help flush away dirt and debris. Wet of the surface, and then work upward. When rinsing, start at entire surface to prevent streaking. the top and work downward—gravity will help the clean water flush away dirt, debris, and detergent residue.
Repair & Maintenance ■ 311
Conversion Table
Converting Measurements
To Convert: To: Multiply by: To Convert: To: Multiply by:
Inches Millimeters 25.4 Millimeters Inches 0.039
Inches Centimeters 2.54 Centimeters Inches 0.394
Feet Meters 0.305 Meters Feet 3.28
Yards Meters 0.914 Meters Yards 1.09
Miles Kilometers 1.609 Kilometers Miles 0.621
Square inches Square centimeters 6.45 Square centimeters Square inches 0.155
Square feet Square meters 0.093 Square meters Square feet 10.8
Square yards Square meters 0.836 Square meters Square yards 1.2
Cubic inches Cubic centimeters 16.4 Cubic centimeters Cubic inches 0.061
Cubic feet Cubic meters 0.0283 Cubic meters Cubic feet 35.3
Cubic yards Cubic meters 0.765 Cubic meters Cubic yards 1.31
Pints (U.S.) Liters 0.473 (lmp. 0.568) Liters Pints (U.S.) 2.114 (lmp. 1.76)
Quarts (U.S.) Liters 0.946 (lmp. 1.136) Liters Quarts (U.S.) 1.057 (lmp. 0.88)
Gallons (U.S.) Liters 3.785 (lmp. 4.546) Liters Gallons (U.S.) 0.264 (lmp. 0.22)
Ounces Grams 28.4 Grams Ounces 0.035
Pounds Kilograms 0.454 Kilograms Pounds 2.2
Tons Metric tons 0.907 Metric tons Tons 1.1
Lumber Dimensions Liquid Measurement Equivalents
Nominal - U.S. Actual - U.S. Metric 1 Pint = 16 Fluid ounces = 2 Cups
1×2 3
⁄4 × 1 1 ⁄ 2 " 19 × 38 mm 1 Quart = 32 Fluid ounces = 2 Pints
1×3 3
⁄4 × 2 1 ⁄ 2 " 19 × 64 mm 1 Gallon = 129 Fluid ounces = 4 Quarts
1×4 3
⁄4 × 3 1 ⁄ 2 " 19 × 89 mm
1×5 3
⁄4 × 4 1 ⁄ 2 " 19 × 114 mm Converting Temperatures
1×6 3
⁄4 × 5 1 ⁄ 2 " 19 × 140 mm
Convert degrees Fahrenheit (F) to degrees Celsius (C) by following this simple
1×7 3
⁄4 × 6 1 ⁄4 " 19 × 159 mm
formula: Subtract 32 from the Fahrenheit temperature reading. Then mulitply that
1×8 3
⁄4 × 7 1 ⁄4 " 19 × 184 mm
number by 5⁄9. For example, 77°F - 32 = 45. 45 × 5⁄9 = 25°C.
1 × 10 3
⁄4 × 9 1 ⁄4 " 19 × 235 mm
1 × 12 3
⁄4 × 111⁄4" 19 × 286 mm To convert degrees Celsius to degrees Fahrenheit, multiply the Celsius temperature
1 1 ⁄4 × 4 1 × 3 1⁄ 2" 25 × 89 mm reading by 9⁄5, then add 32. For example, 25°C × 9⁄5 = 45. 45 + 32 = 77°F.
1 1 ⁄4 × 6 1 × 5 1⁄ 2" 25 × 140 mm
1 1 ⁄4 × 8 1 × 7 1 ⁄4 " 25 × 184 mm
Fahrenheit Celsius
11⁄4 × 10 1 × 9 1 ⁄4 " 25 × 235 mm
11⁄4 × 12 1 × 111⁄4" 25 × 286 mm
1 1⁄ 2 × 4 1 1 ⁄4 × 3 1 ⁄ 2 " 32 × 89 mm
1 1⁄ 2 × 6 1 1 ⁄4 × 5 1 ⁄ 2 " 32 × 140 mm 55° 25°
1 1⁄ 2 × 8 1 1 ⁄4 × 7 1 ⁄ 2 " 32 × 184 mm 50° 20°
11⁄2 × 10 1 1 ⁄4 × 9 1 ⁄ 2 " 32 × 235 mm 45° 15°
11⁄2 × 12 11⁄4 × 111⁄2" 32 × 286 mm 40° 10°
2×4 1 1⁄ 2 × 3 1⁄ 2" 38 × 89 mm 35° 5°
2×6 1 1⁄ 2 × 5 1⁄ 2" 38 × 140 mm 30° Freezing 0°
2×8 1 1⁄ 2 × 7 1⁄ 2" 38 × 184 mm 25° −5°
2 × 10 1 1⁄ 2 × 9 1⁄ 2" 38 × 235 mm 20° −10°
2 × 12 11⁄2 × 111⁄2" 38 × 286 mm 15° −15°
3×6 2 1⁄ 2 × 5 1⁄ 2" 64 × 140 mm 10° −20°
4×4 3 1⁄ 2 × 3 1⁄ 2" 89 × 89 mm 5° −25°
4×6 3 1⁄ 2 × 5 1⁄ 2" 89 × 140 mm 0° −30°312 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
Resources Anchor Wall Systems NovaBrik 877-295-5415 866-678-BRIK (2745) www.anchorwall.com www.novabrik.com
Becker Architectural Concrete Quikrete 651-554-0346 Cement and concrete products www.beckerconcrete.com 800-282-5828 www.quikrete.com Belgard Pavers 800-899-8455 Red Wing Shoes Co. www.belgardpavers.com Work shoes and boots shown throughout book 800-733-9464 Black & Decker www.redwingshoes.com Portable power tools and more www.blackanddecker.com Seattle Glass Block 425-483-9977 Cultured Stone Corporation www.seattleglassblock.com 800-255-1727 www.culturedstone.com Stanley Tools 800-262-2161 Estudio Arqué www.stanleytools.com
- 34-956-695-896 or + 34-690-656-675 email: info@estudioarque.com U-Line www.estudioarque.com 414-354-0300 www.u-line.com Kemiko Concrete Floor Stain 903-587-3708 www.kemiko.com
Photography Credits Anchor Block Clive Nichols p. 9 (lower right) p. 80 Hampton Court 2002 / Mercedes-benz. Designer: Jane Monney: Bright blue wall and raised bed planted Belgard with herbaceous plants. Sculpture by John Brown p. 9 (top right), 10 (lower left), 11 (lower), 12 (lower), 15 (top two) Novabrik p. 262 Cultured Stone Corp. p. 256 Jerry Pavia p. 6, 9 (top left), 15 (lower), 169, 188, 206, 207 (lower Derek Fell’s Horticultural Library two), 226, 232 p. 9 (lower left) Photolibrary / www.photolibrary.com Eldorado 10 (lower middle) Andrew Lord, 10 (lower right), 12 (top), p. 11 (top) 13,14
Tony Giammarino Room & Board p. 227 (lower) p. 5 (top right), 244
iStock / www.istockphoto.com Beth Singer p. 8 (both), 170, 211 (both), 234 p. 250
Resources & Photo Credits ■ 313
Index
A mortar, mixing and placing, step-by-step, 102–107
Acid-stained concrete patios, 118–119 Cast veneer stone, installing,
242–243 planning, 112–113 260–261
Acrylic fortifiers, 22, 28 practice runs, 115 Cement
Aggregate finish for concrete, 35 reinforcing, 114 for concrete repairs, 284
Aggregate stone patio idea, 9 single laying technique, 124–127 surface bonding for stucco finish
Air-entrained concrete, 33 Brick repairs look, 130, 131
Air voids, filling, 144 about, 298 Chimney caps, repairing & replacing,
Anchor bolts, installing in epoxy for chimney caps, 302 303
concrete piers, 45 chimney caps, casting and Chisels, choosing, 177
Archways, building brick, 156–159 installing replacement, 303 Circular paver patios, building, 225
Arroyos, constructing damaged, replacing, 300–301 Circular saws, cutting stone with,
about, 194 deteriorated mortar joints, 177
plan for, 195 replacing, 299 Clay tile patio idea, 13
step-by-step, 195–197 mortar blending, 298 Cobblestone, about, 175, 219
Ashlar Bricks Cobblestone patio idea, 10
about, 175 angle cutting, 115, 116 Cobblestone paver patios, building
for firepits, 198 pressure-washing, 310–311 about, 219
as risers for flagstone garden scoring & cutting, 115, 116, 117 cross section of design, 220
steps, 211 types of, 110 curved, 224–225
Ashlar construction, described, 181 water absorption rate test, 115 design layout detail, 220, 223
Brick splitters, using, 117 idea for, 218
Brick veneer column idea, 11 step-by-step, 221–224
B Brick veneer walls Color
Bagged concrete mix, 22, 27, 95 about, 160 acid-staining, 242–243
Bankers, 176 anatomy of, 160 blending mortar for brick repairs,
Batter gauges, using, 181 installing, 161–163 298
Birdbaths, cast concrete, 95 Broomed finish for concrete, 34 consistency in concrete, 85, 292
Black dirt, about, 171 Brown coat (stucco), 251 for mortar, 119
Bleed water Building codes painting concrete, 249
about, 33 arroyos and, 194 pretinted concrete, 92
workability of concrete and, 19 firepits and, 198 stucco, 252
Block projects footings and, 44, 46 Columns
concrete blocks, cutting, 117 outdoor kitchens and, 139 brick veneer idea for, 11
estimating amount needed, 112 steps and, 56 building brick, 152–155
laying technique, 124–127 Buttering, 120 cast concrete, building, 96–97
planning, 112–113 Compactable gravel, 171
reinforcing, 114 Concrete
Blocks, types of, 110 C applying stamped finishes,
Bowls, cast concrete, 95 Cantilever walls, 87 240–241
Braces, securing on concrete slabs, Cap pieces, 127 blocks, cutting, 117
83 Capstones coloring by acid-staining, 242–243
Brick archways, building, 156–159 for pillars, 155 color & texture consistency in, 85
Brick barbecues, building, 146–149 for walls, 149 components of, 19
Brick moon windows, building, Cast concrete costs, 27
214–217 forms for, making, 94–95 coverage, 25
Brick patios, building mortared, forms for, prefabricated, 96 curing & finishing, 34–35
164–167 garden columns, building, 96–97 delivery, steps before, 26
Brick pavers, about, 219 ideas for, 10, 12, 94, 95 estimating amount needed, 25,
Brick pillars, building, 152–155 patio tabletops, building, 98–99 101
Brick planters, building, 150–151 reinforcing large objects, 95 materials for, 22–23
Brick projects Cast concrete kitchen countertops, materials for kitchen countertops,
double layering technique, building 101
120–123 about, 100 mixing, 28–29
estimating amount needed, 112 planning, 101 ordering, 26314 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
placing, 30–33 pouring, 44–45 Concrete slabs, poured concrete posts, setting in, 42–43 Concrete, poured acid-staining, 242–243 sealing, 96 decorative floors, 244–249 building, 68–71 slippery, 28 footings for freestanding walls, renewing, 290–293 tools for, 20–21 46–49 Concrete slabs, tiling workability indications, 19 idea for, 10 about, 268 Concrete and weather J-bolts and, 44, 68 control joints, 270 bleed water, 33 for outdoor kitchen countertops, materials needed, 269 day of pour and, 26 143–144 step-by-step, 271–275 drainage and, 87 piers, 44–45 surface evaluation, 270 frost heave and slabs, 68 Concrete, poured paths tile options, 269 frost line and footings, 36, 44, 46, about, 50 tools needed, 269 62 building, 52–55 Concrete steps frost line and isolation boards, 58 reinforcing options, 51 building, 58–61 Concrete block outdoor kitchens sloping options, 51 designing, 56–57 about, 138 Concrete, poured patios next to forms for, 41 building, 140–145 house, 76 idea with flagstone for, 207 construction details, 139 Concrete, poured retaining walls repairing, 294–295 planning, 139 about, 87–88 Concrete steps, freestanding Concrete block projects building, 89–93 about, 62–63 blocks, cutting, 117 ideas for, 18, 86 building, 64–67 estimating amount needed, 112 types of, 87 Concrete steps, tiling laying technique, 124–127 Concrete, poured round patios about, 276 planning, 112–113 about, 72–73 step-by-step, 277–281 reinforcing, 114 building, 75–79 Corners, patching concrete, 294 Concrete block retaining walls curves, forming, 73 Counterfort walls, 87 building, 134–136 foundational elements, 74 Countertops, building cast concrete building with curve, 137 Concrete, poured walls kitchen idea for, 132 about, 80 about, 100 Concrete block walls, building dry, building, 84–85 planning, 101 130–131 on concrete slabs, 83 step-by-step, 102–107 Concrete, cast forms for, 41, 80, 81–82 Cracks, patching concrete, 286–287 forms for, making, 94–95 Concrete projects Crushed limestone, 171 forms for, prefabricated, 96 forms, building & installing, 40–41, Crushed quartz, 171 garden columns, building, 96–97 80, 81–82 Crushed rock, 171 ideas for, 10, 12, 94, 95 planning & preparation for, 19, 24 Curb walls, 87 patio tabletops, building, 98–99 site, laying out & excavating, Curves, building forms for, 41, 73 reinforcing large objects, 95 38–39 Cutting zones, 176 Concrete floors, decorative site preparation for, 36–37 about, 244 steps before delivery, 26 painting, 249 Concrete, repairing D sealing concrete, 245–247 about, 284 Decorative columns/pillars staining, 248 corners, patching, 294 brick veneer idea for, 11 Concrete patios cracks, patching, 286–287 building brick, 152–155 acid-staining, 242–243 large holes, patching, 285 cast concrete, building, 96–97 idea for, 9 shaped concrete, 296 Decorative concrete floors Concrete paver patios, building slab renewal, 290–293 about, 244 about, 219 small holes, patching, 284 painting, 249 cross section of design, 220 wet walls, 288 sealing concrete, 245–247 curved, 224–225 Concrete, shaped, 296 staining, 248 design layout detail, 220, 223 Concrete slabs Double-wythe brick walls, described, idea for, 218 amount needed for varied 112 step-by-step, 221–224 thicknesses and surface areas, Drawings, scaled plan, 24–25 Concrete piers 25 Dressing stone, 177 anchor bolts, installing in epoxy, renewing, 290–293 Dry block walls, building, 130–131 45
Index ■ 315
Dry-laid/dry-stacked masonry, about, Forms I
109 for brick archways, 156, 157 Inspections, 26
Dry stone walls building, 40–41 Interlocking block retaining walls
building, 182–183 for casting concrete, making, building, 134–136
rebuilding section, 305 94–95 with curve, 137
Dry streambeds, constructing for casting concrete, idea for, 132
about, 194 prefabricated, 96 Interlocking concrete paver patios,
plan for, 195 for curves, 41, 73 building
step-by-step, 195–197 decorative elements, adding, 91 about, 219
preparing, 19 cross section of design, 220
for steps, 41 curved, 224–225
E steps completed before concrete design layout detail, 220, 223
Entryway steps, freestanding delivery, 26 idea for, 218
concrete for walls, 41, 80, 81–82 step-by-step, 221–224
about, 62–63 Foundation walls, building, 128–129 Isolation boards and frost line, 58
building, 64–67 Framed walls Isolation joints, importance of, 37
Exposed aggregate finish for applying stucco finish, 254–255
concrete, 35 preparation of, for stucco finish,
Exposed aggregate stone patio idea, 253 J
9 Freestanding concrete steps Japanese gardens, making, 234–236
Epoxy for installing anchor bolts, 45 about, 62–63 J-bolts
building, 64–67 poured concrete piers and, 44
Frost heave and slabs, 68 poured concrete slabs and, 68
F Frost line Joints
Fieldstone footings and, 36, 44, 46, 62 control, in concrete patios, 270
about, 175 isolation boards and, 58 deteriorated mortar, replacing,
cutting, 178 299
Finish coat (stucco), 251, 252 in dry stone walls, 180
Firepits, building stone, 198–201 G isolation, 37
Flagstone Garage foundations, building, 68–71 in mortared stone walls, 184
about, 175 Garden columns repointing mortar, in stone walls,
cutting, 178 brick, building, 152–155 306
Flagstone garden steps, building cast concrete, building, 96–97
cross section of design, 207 Garden steps, building flagstone
estimating amount of flagstone cross section of design, 207 K
needed, 206 estimating amount of flagstone Kitchen countertops, building cast
ideas for, 206, 207, 211 needed, 206 concrete
step-by-step, 208–210 ideas for, 206, 207, 211 about, 100
Flagstone patios, building mortared, step-by-step, 208–210 planning, 101
202–205 Granite, 174 step-by-step, 102–107
Flagstone patios, building sandset Gravel
choosing materials for, 227 about, 171
construction details, 228 estimating amount needed, 25 L
idea for, 226 for post holes, 43 Landscape steps, freestanding
plant choices for, 231 sub-base for concrete projects, 37 concrete
soils for, 231 Gravity walls, 87 about, 62–63
step-by-step, 229–231 Grills for outdoor kitchens, 139 building, 64–67
Floating footings, pouring, 147 Grout, applying on tiled surfaces, Latex bonding agents, 22, 28
Floors, decorative concrete 275 Laying brick
about, 244 double layering, 120–123
painting, 249 single, 124–127
sealing and, 245–247 H Limestone, 171, 174
staining, 248 Handrails, 211 Liquid concrete products, 22
Footings Holes
frost line and, 36, 44, 46, 62 in cement, patching large, 285
poured concrete, for freestanding in cement, patching small, 284 M
walls, 46–49 in stucco, repairing, 308 Masonry
pouring floating, 147 Honeycombs, filling, 144 about, 109
mortar mixes, 110316 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
pressure-washing, 310–311 step-by-step, 208–210 tools needed, 269 tools for, 111 Natural stone paths idea, 170 Patios, mortared brick, building, types of bricks and blocks, 110 Natural stone patios, building 164–167 See also Block projects; Entries sandset flagstone Patios, mortared flagstone, building, beginning with Brick or Bricks choosing materials for, 227 202–205 Masonry anchors, 44 construction details, 228 Patios, poured concrete next to Masonry veneer, repairing, 297 idea for, 226 house, 76 Moon windows, building stone, plant choices for, 231 Patios, round poured concrete 214–217 soils for, 231 about, 72–73 Mortar step-by-step, 229–231 building, 75–79 blending for brick repairs, 298 Natural stone retaining walls, curves, forming, 73 for concrete repairs, 284 building foundational elements, 74 mixes, 110 about, 188 Patios, sandset flagstone, building mixing and placing, 118–119 cross sections of design, 189 choosing materials for, 227 paver compatibility, 164 step-by-step, 190–193 construction details, 228 removing, 187 Natural stone retaining walls ideas, idea for, 226 for stone veneer, 258 8, 9, 188 plant choices for, 231 for tuck-pointing, 119 Natural stone walls soils for, 231 types of, 146 dry stone, building, 182–183 step-by-step, 229–231 Mortared brick patios, building, mortared stone, building, 184–187 Patio tabletops, building cast 164–167 concrete, 98–99 Mortared flagstone patios, building, Paver cobblestone patios, building 202–205 O about, 219 Mortared stone walls One-coat, fiberglass-reinforced coat cross section of design, 220 building, 184–187 (stucco), 251, 252 curved, 224–225 repairing, 306 Outdoor kitchens design layout detail, 220, 223 replacing section, 307 about, 138 idea for, 218 Mortar joints building, 140–145 step-by-step, 221–224 replacing deteriorated, 299 construction details, 139 Pavers repointing in stone walls, 306 planning, 139 about, 219 Mortarless block walls, building, building patios with, 164–167 130–131 and weather, 164 Mortarless veneer brick siding, P Pea gravel, 171 installing Paths, ideas for, 13, 15, 170, 232 Pebbled stepping stone paths, about, 262 Paths, pebbled stepping stone, building, 232–233 step-by-step, 263–267 building, 232–233 Permits, 24, 26 Mortar mixes, 110 Paths, poured concrete Pillars about, 50 brick veneer idea for, 11 building, 52–55 building brick, 152–155 N reinforcing options, 51 cast concrete, building, 96–97 Natural stone sloping options, 51 Pitching chisels, 177 about, 170 Patio ideas, 9, 10, 13, 218, 226 Plan drawings choosing stone for projects, 174 Patios, cobblestone paver, building importance of, 24–25 cutting, 176–177 about, 219 for steps, 57 cutting fieldstone, 178 cross section of design, 220 Planters cutting with circular saw, 178 curved, 224–225 building brick, 150–151 estimating amount needed, 170 design layout detail, 220, 223 ideas for, 10, 12 hauling, 171 idea for, 218 Plants laying, 180–181 step-by-step, 221–224 for retaining walls, 193 lifting & moving, 176 Patios, concrete for sandset flagstone patios, 231 tools for, 172–173 acid-staining, 242–243 Plywood for forms, 41 types & forms of, 171, 174–175 control joints in, 270 Pointing chisels, 177 Natural stone firepits, building, idea for, 9 Popped stones, repairing, 304 198–201 Patios, concrete slab, tiling Posts, setting in concrete, 42–43 Natural stone garden steps, building about, 268 Poured concrete flagstone control joints, 270 footings for freestanding walls, cross section of design, 207 materials needed, 269 46–49 estimating amount of flagstone step-by-step, 271–275 idea for, 10 needed, 206 surface evaluation, 270 J-bolts and, 44, 68 ideas for, 206, 207, 211 tile options, 269
Index ■ 317
for outdoor kitchen countertops, Retaining walls, poured concrete Stamped concrete finishes, applying,
143–144 about, 87–88 240–241
Poured concrete decorative floors building, 89–93 Steppers, described, 227
about, 244 ideas for, 9, 10, 18, 86 Stepping stone paths
painting, 249 types of, 87 building pebbled, 232–233
sealing concrete, 245–247 Retaining walls, terraced ideas for, 13, 232
staining, 248 ideas for, 10, 132 Steps
Poured concrete paths River rock, 171 handrails for, 211
about, 50 Rock gardens, building, 212–213 ideas for, 8, 206, 207, 211
building, 52–55 Round patio tabletops, building cast Steps, building flagstone garden
reinforcing options, 51 concrete, 98–99 cross section of design, 207
sloping options, 51 Rubble, 175 estimating amount of flagstone
Poured concrete retaining walls needed, 206
ideas for, 9, 10, 18, 86 ideas for, 206, 207, 211
positioning options, 133 S step-by-step, 208–210
structural features, 133 Safety tools and equipment, 21, 173 Steps, concrete
Poured concrete slabs Sand, about, 171 building, 58–61
acid-staining, 242–243 Sand casting, 95 designing, 56–57
building, 68–71 Sandset flagstone patios, building forms for, 41
renewing, 290–293 choosing materials for, 227 repairing, 294–295
Poured concrete walls construction details, 228 Steps, freestanding concrete
about, 80 idea for, 226 about, 62–63
building, 84–85 plant choices for, 231 building, 64–67
on concrete slabs, 83 soils for, 231 Steps, tiling concrete
forms for, 41, 80, 81–82 step-by-step, 229–231 about, 276
Power mixers for concrete, using, 29 Sandsetting stones, about, 202 step-by-step, 277–281
Prefabricated forms for casting Sandstone, 174 Stone chisels, 177
concrete, 96 Scaled plan drawings, 24–25 Stone firepits, building, 198–201
Premixed concrete Scratch coat (stucco), 251 Stone garden steps, building
advantages of, 26 Semigravity walls, 87 flagstone
costs of, 27 Shaped concrete, repairing, 296 cross section of design, 207
Pressure-washing masonry, 310–311 Shiners, 181 estimating amount of flagstone
Siding, mortarless veneer brick, needed, 206
installing ideas for, 206, 207, 211
R about, 262 step-by-step, 208–210
Railings, installing, 61 step-by-step, 263–267 Stone paths, building pebbled
Rain gardens, described, 197 Siding, veneer stone idea for, 11 stepping, 232–233
Readymix concrete Single-wythe block walls, described, Stone patios, building sandset
advantages of, 26 112 flagstone
costs of, 27 Single-wythe brick walls, described, choosing materials for, 227
Rebar, tips for working with, 41 112 construction details, 228
Refactory mortar, 146 Slab-on-grade foundations, building, idea for, 226
Remesh, tips for working with, 41 68–71 plant choices for, 231
Retaining walls Slabs for mortared brick patios, 164 soil for, 231
ideas for, 8, 9, 10, 18, 86, 132, 188 Slabs, poured concrete step-by-step, 229–231
planting, 193 acid-staining, 242–243 Stone retaining walls, building
positioning options, 133 building, 68–71 natural
structural features, 133 renewing, 290–293 about, 188
Retaining walls, building stone Slate, 174 cross sections of design, 189
about, 188 Slippery concrete, 28 plants for, 193
cross sections of design, 189 Slopes step-by-step, 190–193
planting, 193 ideas for, 8, 9, 10, 132 Stone retaining walls ideas, 8, 9, 188
step-by-step, 190–193 measuring, 37 Stone slab steps idea, 8
Retaining walls, interlocking block poured concrete walkways for, 51 Stone veneer
building, 134–136 rock gardens for, 212–213 about, 256
with curve, 137 See also Retaining wall entries estimating amount needed, 256
idea, 132 Soil for sandset flagstone patios, 231 walls, finishing with, 257–259
Retaining walls, natural stone Stacked stone walls idea, 9 Stone walls, dry, repairing, 304–305
ideas for, 8, 9, 188 Stairs, ideas for, 12, 15 Stone walls, mortared
repairing, 306318 ■ THE COMPLETE GUIDE TO MASONRY & STONEWORK
replacing section, 307 U building, 84–85 Stone walls, natural Utilities and outdoor kitchens, 139 on concrete slabs, 83 dry stone, building, 182–183 forms for, 41, 80, 81–82 mortared stone, building, 184–187 V Walls, stacked stone Stonework, pressure-washing, Veneer brick column idea, 11 footings for, 47 310–311 Veneer brick siding, installing idea for, 9 Story poles, 39 mortarless Water management Stucco finish about, 262 brick water absorption rate test, about, 9, 250 step-by-step, 263–267 115 applying, 254–255 Veneer brick walls drainage and concrete, 87 base coat calculator, 250 about, 160 dry streambeds, constructing, for outdoor kitchens, 145 anatomy of, 160 194–197 preparation of framed walls for, installing, 161–163 erosion & damage to dry-stone 253 Veneer, repairing masonry, 297 walls, 305 surface bonding cement to look Veneer stone repairing wet walls and, 288 like, 130, 131 about, 175 Weather and concrete texturing, 252 cast, installing, 260–261 bleed water, 33 types of systems, 251 for siding, 11 day of pour and, 26 Stucco, repairing drainage and, 87 about, 308 frost heave and slabs, 68 large areas, patching, 309 W frost line and footings, 36, 44, 46, small areas, patching, 308 Walkways. See Entries beginning 62 with Paths frost line and isolation boards, 58 Walls Weather and pavers, 164 T applying stucco finish, 254–255 Wet walls, concrete repairs, 288 Tabletops, building round patio cast concrete repairs for wet, 288 Wood forms, building, 40–41, 47 concrete, 98–99 foundation, building, 128–129 Wood posts, setting in concrete, Terracing ideas, 10, 132 with moon windows, 214–217 42–43 Texture consistency in concrete, 85 poured concrete footings for Three-coat stucco, about, 251 freestanding, 46–49 Throwing mortar preparation of framed, for stucco Z practice bricks for, 115 finish, 253 Zen garden rakes, making, 237 technique for, 118–119 See also Retaining walls Zen gardens, making, 234–236 Tie stones, 181 Walls, block Tiles footings for, 47 cutting contours in, 273 Walls, brick grouting porous, 275 double layering technique, Tiles, installing on concrete slabs 120–123 about, 268 footings for, 47 control joints, 270 single laying technique, 124–127 materials needed, 269 Walls, brick veneer step-by-step, 271–275 about, 160 surface evaluation, 270 anatomy of, 160 tile options, 269 installing, 161–163 tools needed, 269 Walls, concrete block Tiles, installing on concrete steps laying technique, 124–127 about, 276 mortarless, building, 130–131 step-by-step, 277–281 Walls, dry stone Tools building, 182–183 for concrete projects, 20–21 idea for patio and, 227 for masonry projects, 111 rebuilding section, 305 for natural stone, 172–173 Walls, mortared stone for tile installations, 269 building, 184–187 Trap rock, 171 repairing, 306 Treads on steps, patching, 295 replacing section, 307 Tuck-pointing, mortar for, 119 Walls, natural stone Two-coat stucco, 251 dry stone, building, 182–183 Type M mortar, 182 mortared stone, building, 184–187 Type N mortar, 146 Walls, poured concrete Type S mortar, 146 about, 80
Index ■ 319CREATIVE PUBLISHING international
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