Brick and Stone Repair

Common Reasons for Brick and Stone Repair

There are a multitude of reasons why you may need your brick or stone repaired. Some of the most common ones are:

• Foundation Settlement
• Leaning Brick or Stone Walls or Mailbox
• Brick or Stone Retaining Wall Damage
• Cracked Brick, Stone, or Mortar
• Eroded Mortar
• Physical Damage

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Leaning / Tilting Brick or Stone Structures

This is most often seen when brick and stone structures begin leaning with the potential to completely fall over. Retaining walls, freestanding walls, mailboxes and stone borders are known to fail over time due to a combination of reasons.

The most common mistake is building a structure without a solid concrete footing or foundation. Many times contractors negate this step in hopes of rushing through a job and quickly sell the customer stating the “footing” is an optional item. Sooner than later all that brick or stone work will begin moving as the dirt below begins to expand and contract throughout seasonal weather changes. The masonry structure will begin cracking along the mortar joints and eventually start tilting and leaning over due to the lack of stability from the missing foundation.

Water or drainage concerns are the next cause of leaning structures and should be addressed to prevent future damage due to accumulating water near the masonry structure. Gutters and downspouts may need to be altered to accommodate heavy water flow during torrential rain and heavy downpours. Many times a separate drain system may be recommended to prevent freestanding water from over saturating and flooding a nearby stone border or rock retaining wall.

It is essential all structures are supported with a solid concrete footing and potential flooding hazards should be identified in order to prevent leaning/ tilting and ultimately prolong the life of your surrounding hardscape structures.

Cracked Brick, Stone, or Mortar

Mortar joints are often found eroded, cracking, or separated throughout many types of brick and stone structures. Most exterior brick on houses, retaining walls, and patios are susceptible to deterioration over the years. The severity of the cracks will determine the best repair solution. Almost all properties tend to move at some point over the life span of construction.

Foundation settlement is well known to cause these unsightly cracks and separation along the exterior brick and mortar. Many times these cracks may be repaired in place while removing and replacing the mortar with chisels and grinders. Cracked or damaged brick can be cut out and replaced with new replacement brick.

On the other hand, severe cracking and separation over 1” may call for a more in depth repair process. For example, all the brick surrounding a window or entry door may need to be completely removed and replaced from the ground up to provide the best solution.

We always recommend having your foundation assessed by an engineer prior to performing any masonry repairs. This will ensure you’re following the proper procedures and avoid any additional cost of having prior brick and mortar work repaired again.

Eroded Brick or Mortar

Over time masonry surfaces will begin to crumble, disintegrate, and fall apart due to the surrounding elements. Constant sunshine, wind, and heavy rainfall can all contribute to the natural decay of masonry structures. This is commonly seen where mortar joints have collected dirt and grime caused from nearby water runoff onto surrounding brick, stone, and mortar. You’ll notice loose pieces of mortar that have become dislodged and are ready to fall out. Simply touching the mortar with your bare hand will cause it to easily crumble and disintegrate. Spalling brick is a term used to describe brick and stone that has eroded over time. The face of the brick begins to crack followed by layers of brick that start to flake and fall off leaving a fragile and weakened masonry structure.

It’s important to take note of any areas receiving heavy rainfall and incorporate the necessary drainage to prevent further erosion and spalling of the brick and mortar surfaces. Type N or type S mortar is commonly used for masonry repairs and should be properly mixed with the correct ratios of sand, mortar, and water. Do not apply a flexible non breathable sealant for a quick fix as it will trap all moisture behind the sealant eventually leading to erosion as the trapped water has no way to escape! Both brick and mortar are designed to expand and contract while absorbing and releasing water as weather permits in the outside elements.

Physical damage

Unfortunately, many mailboxes, buildings, and homes are frequently hit by vehicles causing immediate damage that must be repaired or completely replaced. We receive many calls where an inattentive driver lost control of their car and completely demolished a nearby mailbox. This typically calls for a complete mailbox replacement as the remaining brick debris is far damaged beyond repair.

We also receive calls in regards to a damaged section of wall that was accidentally hit while a homeowner was attempting to park in the garage or position a trailer on their driveway. The damaged section of brick may be simply cut out, removed, and rebuilt in order to avoid replacing the remaining section of wall which wasn’t affected from the initial vehicle impact.

Natural disasters such as tornadoes, flooding, and high winds have been known to cause physical damage that may need repair or full replacement.

The list above covers some of the most common causes of masonry repair and brick replacement. It’s essential to know the contributing factors which lead to brick and stone repair in order to prolong the life of your home and surrounding hardscape structures. You’re welcome to leave your contact info online and we will reach out to discuss your masonry repair request, schedule an on site assessment, and provide you with a written estimate covering your line items of concern.

First, scope out the areas along the exterior walls needing mortar repair and commit to preparing the joint lines by removing the defective mortar

Tools for cleaning out joints range from electric angle grinders, hammers, and chisels. Please ensure you have the appropriate PPE applicable to the job including, gloves, ear plugs, face mask, and most importantly eye protection.

Start by applying the angle grinder across the damaged mortar joint using a firm grip and allowing the blade to gently move across the affected surface.

No need to push hard or force the blade across the surface as it will cut extremely well with minimal pressure. Please be aware of the surrounding brick while cutting in order to avoid damaging the brick facing or surface.

Next, use your hammer and chisel to clean out the remaining grout and debris inside the mortar joint surface.

Typically, mortar joints should be scraped out a minimum of ⅝ – ¾ of an inch. A general rule is to go 2 times the size of the joint width and anything over a ½” joint may need a deeper cut. You may now clean off any remaining pieces of mortar and debris with a stiff bristled brush. This is an important step to ensure the joint cavities are fully cleaned out to allow for the strongest bond between the new and existing mortar.

Now, take a moment to dampen the surrounding mortar joints and brick with a mist of water to prevent a loss of moisture during the mortar curing process.

Mortar mixing starts by combining sand and mortar with water or you may simply use a pre-mix mortar that only requires adding water. Mix just enough to cover your general work area. We recommend a sand/ mortar ratio of 3:1 and you should gradually add water while mixing to prevent over saturating the mix into a sloppy mess. Let the mortar set up 10-15 minutes until it becomes thick like peanut butter.

Now you’re set to take your trowel or grout bag and begin the pointing process of filling in the prepped mortar joints.

Start filling your joints working from the top down. Point all your vertical joints first followed by the surrounding horizontal joints working from top to bottom of the work area.

Next, wait for the mortar to begin hardening and the joints will be ready to strike and clean once the mortar is thumbprint hard – meaning you place your thumb on the mortar and no residue sticks to your skin.

You may now pack down the mortar with a joint striker also known as “tooling” the joints. The most common concave joint is usually found on most residential homes; however, others may achieve a flat joint by simply troweling out or scraping off the excess mortar. Do your vertical joints first followed by the surrounding horizontal and work inwards off the corners to prevent pulling mortar out of the joint.

Finally, take a soft masonry brush and clean off any remaining mortar by brushing diagonally across the work surface.

You may also use a damp sponge with water to wipe off mortar residue that may have been left on the brick surface during the repair process.

Do you need masonry work in the DFW area?

Superior Masonry strives to help our customers with quality masonry work and excellent service.

If you need masonry work in the DFW area, please call, email, or use our online form to schedule your free estimate and consultation. We look forward to hearing from you!

972-433-9372 – info@superiormasonrydallas.com
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