Masonry is the craft of building structures from stone, brick, concrete, and other similar materials. It involves stacking materials and using mortar to bind the units together.
Learning about masonry requires knowledge of the different materials, techniques, and applications for both professionals and do-it-yourself (DIY) enthusiasts. Whether you’re considering embarking on a new project or just want to understand the craft better, here’s what to know.
Essential Materials in Masonry
Masonry relies on a few key materials, each with different properties and applications.
Stone
Stone is a basic masonry material. It can create walkways and walls without mortar, instead using the weight and friction between stones for stability. Stone masonry offers a natural, rustic appearance with great durability. Different types of stone, such as granite, limestone, or sandstone, can be chosen based on local availability and the desired look.
Pro Tip: David Peabody, mason with Smith & May, advises: “You find a stone with a shape that’s in the ballpark and work with it. You find about one or two stones per week that fit naturally, with a consistent joint.”
Brick
Bricks are made from clay and sand and shaped into stackable forms. They offer consistency in size and shape, making them easier to work with than natural stone. Bricks come in various colors and textures, allowing for diverse architectural designs. Their uniform size also facilitates more precise and faster construction than irregular stones.
The brick’s final color depends heavily on the local clay composition. “The main ingredient in a brick is clay. The type of clay that we find in Cambridge, Massachusetts is much different than the clay that we find, say down in South Carolina, there’s a deep red clay that we find down there. And that’s why you’ll get a deep red brick out of South Carolina. You go out towards the western part of the country and you’ll find different colors. I know out in the Milwaukee area, for instance, they have a yellowish clay which actually makes the brick yellow after they’re cooked.”
Mortar
Mortar is the binding agent used to hold masonry structures together. Modern mortar is typically a mixture of Portland cement, sand, and water. It may also include lime to improve workability and adhesion. Mortar binds blocks and helps distribute loads evenly across the structure. Different types of mortar are formulated for specific applications, such as laying brick, cinderblocks, or stone.
Pro Tip: Mark McCullough, This Old House mason, advises on choosing the right mortar type: “Type S—think strength. So elevator shafts, stair shafts, retaining wall, foundation. Type N is what we strictly use for brick work. It gives a little bit of movability to the brick because everything’s a natural material, don’t forget.”
Concrete
Concrete is a versatile material used in many aspects of masonry construction. It combines gravel, sand, Portland cement, and water. Concrete can be used for foundations, slabs, and even precast blocks. Its ability to be molded into various shapes, combined with its strength and durability, makes it a great component in masonry projects.
Fundamental Principles of Masonry Construction
Masonry construction adheres to several key principles for strength, stability, and longevity. These include proper bonding between units and maintaining level courses for adequate support. Masons also consider load distribution, thermal expansion, and moisture control when designing and building to create durable masonry structures.
Supporting Masonry Work
The foundation of any masonry structure is critical to its longevity and stability. Proper support prevents settling and cracking, ensuring the masonry remains intact for years. Building on stable ground and having footings for even weight distribution is essential to completing a masonry project successfully.
Pro Tip: Mark McCullough, This Old House masonry expert, emphasizes the importance of foundation thickness: “A house like this, usually 12 inches will do,” he notes while examining a particularly robust 20-inch thick foundation. “This is the real reason this foundation is in good condition.”
Stable Ground and Footings
All masonry must be built on stable ground, either undisturbed soil or mechanically compacted fill. Footings are necessary for spreading the weight of the masonry evenly over larger areas to prevent uneven settling. Concrete footings are common, but you can also decide between compacted gravel and crushed stone. The width and depth of the footings will depend on the weight they’ll support and the bearing capacity of the soil.
Frost Depth Considerations
In areas where the ground freezes, footings must extend below the frost line to prevent damage. When water in the soil freezes, it expands, causing potential lifting and cracking along masonry structures. Placing footing underneath the frost line allows your foundation to remain stable throughout temperature changes.
Understanding Concrete
Concrete is very important in many masonry projects, from footings to slabs. Its versatility and molding abilities make it an indispensable construction material.
Pro Tip: Roger from This Old House advises: “The lesson to learn is that every bag has Portland cement in it now, cement and concrete are different things. But Portland cement is the key ingredient to everything you’re gonna make. This is basically the adhesive, this fine powder right here.”
Composition of Concrete
Concrete is composed of gravel, sand, Portland cement, and water. Portland cement, made from fired clay and limestone, acts as the binding agent. When mixed with water, it hardens the mixture, encasing the materials to create the concrete we see on sidewalks and driveways.
Various additives can be incorporated into concrete to modify and alter its properties. Adding fiber reduces the likelihood of your concrete cracking. Plasticizers allow for less water while still being workable. Retarders slow the hardening process (good for hot weather), while accelerators speed up hardening (good for cold conditions). Each of these additives tailors the concrete to specific project requirements and environmental conditions most suitable for you.
Pro Tip: According to concrete specialists at This Old House, “In New England, we add fly ash to our mix, which is a byproduct of coal from power plants.” The reason? “It’s to allow the concrete to be less permeable so water doesn’t penetrate through the concrete. Less water in the concrete, less freeze/thaw.”
Mixing and Curing Process
The mixing process is critical to concrete’s strength. It’s important to add just enough water to make the mix workable, as too much water weakens the finished product. Concrete typically takes about 28 days to fully cure, although it becomes walkable within 12–24 hours. Proper curing involves maintaining moisture and temperature conditions to allow the concrete to reach its full strength.
Pro Tip: Mason Lenny Moreira, with 30 years of experience, advises: “Wetness leads to weakness.” He explains that sidewalks and steps often break or chip because there was too little Portland cement and too much water in the mixture, emphasizing the importance of adding water slowly and sparingly to achieve a spreadable mixture similar to cake frosting.
Types of Masonry Structures
Masonry techniques can be applied to a wide variety of structures, each with its own set of requirements and design considerations. From walls to walkways, patios, and driveways, there are many projects that DIY builders can complete.
The type of masonry structure often depends on regional stone availability. Stones differ by region and type, ranging from the hard granites of New England to the subtle sandstones of the Midwest to the fossil-bearing limestones of the Florida Keys. Because of that—and because different situations call for different boundaries—walls vary too.
Walls
Masonry walls can be load-bearing or non-load-bearing. Load-bearing walls support the weight of the structure’s roof and floors, while non-load-bearing walls serve primarily for partitioning and design purposes. They offer excellent thermal mass, sound insulation, and fire resistance.
When creating openings in masonry walls, the process requires specialized expertise. As TOH mason Lenny Belliveau demonstrated on the Charlestown project, making a window-sized hole in a brick wall requires careful insertion of lintels—long stone or steel supports—above windows and doors to distribute the immense load of the wall above. The wrong sequence of moves could collapse a wall and send tons of brick and mortar spilling to the sidewalk.
Walkways
Stone or brick walkways are popular masonry projects that can enhance outdoor spaces. These structures typically rest on a crushed stone base to provide drainage and allow for slight movement with temperature changes. Walkways add appeal and provide functional routes through a landscaped area.
Pro Tip: Roger Cook, This Old House landscape contractor, advises: “To keep the walk from walking on you, the bed under the brick must be filled with gravel-5 tons of it for this 42-foot path.” He emphasizes that “a walkway is only as good as the base you put under it.”
Patios and Driveways
Masonry patios and driveways are an easy way to create a unique outdoor area. These structures require proper base preparation and often incorporate concrete slabs for stability. Pavers or bricks can be used to create various patterns and designs.
Tools of the Masonry Trade
Masonry work requires a specific set of tools for precision and efficiency in construction. The right tools can significantly affect the quality and speed of work. There are both hand tools and power tools that you’ll want to consider using, especially if you’re new to masonry construction.
Hand Tools
Hand tools are fundamental for achieving detailed and precise masonry work, whether you’re laying bricks, applying mortar, or finishing joints. Essential hand tools for masonry include the following:
- Chisels and hammers for shaping and cutting materials
- Jointers for finishing mortar joints
- Levels for ensuring straight and plumb work
- Trowels for spreading mortar
Power Tools
Power tools are useful for larger projects to reduce the time and effort needed to cut materials and prepare mixtures. A mixer, for example, produces consistent mortar and concrete quality, guaranteeing the strength and durability of masonry structures. Power tools used in masonry work include the following:
- Mixers for preparing mortar and concrete
- Power hammers for breaking up old masonry
- Wet saws for cutting brick and stone
DIY Masonry Projects
While many masonry tasks require professional skills, DIY enthusiasts are equipped to handle several projects.
Walkway Installation
Installing a stone or brick walkway can be a great DIY project. It involves preparing a proper base, laying out the pattern, and carefully setting each block. A well-laid walkway can add character to your outdoor spaces and provide a practical path through garden areas.
Fire Pit Construction
Building a fire pit using precast concrete blocks is an achievable DIY task. It requires minimal tools and can be completed over a weekend. The fire pit provides a focal point for outdoor gatherings, making it a valuable addition to outdoor living spaces.
Basic Repairs and Maintenance
Simple masonry repairs, such as reapplying worn mortar, are possible for many homeowners. Patching concrete and resurfacing worn-down slabs or sidewalks are also manageable DIY tasks that can improve the appearance and longevity of masonry structures. Regular maintenance can prolong the life of masonry work, keeping it durable and long-lasting.
Professional vs. DIY Masonry Work
While some masonry projects are fit for DIYers, many require professional expertise. Large-scale projects often need heavy equipment, specialized tools, and skills from years of experience. Professionals have the knowledge of structural integrity, building codes, and how to complete complex work efficiently.
Professionals understand how different materials interact with environmental conditions like moisture and temperature changes. They have the experience to address these complexities for the long-term success of projects. Homeowners should consider the scale and scope of their intended projects and weigh the potential cost savings of DIY against the benefits of professionals.
Common Masonry Problems and Solutions
Masonry structures, while durable, are not immune to problems. Understanding common issues and solutions to cracking and moisture damage can help you address problems early.
Cracking
Cracks can occur due to settling, thermal expansion, or improper support. Small cracks can often be repaired with masonry caulk, while larger cracks may require professional attention. Identifying the cause of the cracking is important to prevent cracks from reappearing.
Efflorescence
Efflorescence is a white, powdery substance that appears when water-soluble salts move to the surface of masonry. It can often be cleaned with a stiff brush and diluted vinegar, but persistent cases may indicate underlying moisture issues. Improving drainage around the masonry and sealing surfaces can help prevent efflorescence from forming.
Moisture Damage
Excessive moisture can lead to deterioration of masonry materials. Proper drainage, waterproofing, and regular maintenance are key to preventing moisture-related damage. Addressing gutter leaks, having proper grading, and using waterproof sealants can protect masonry from water damage.
Masonry Techniques and Skills
Mastering masonry techniques requires practice and attention to detail. Some skills are foundational, while others might be developed over time.
Laying Bricks and Stones
Proper laying techniques involve maintaining level courses, having consistent mortar joints, and using the appropriate bonding patterns. Each block should be placed with care to create a strong structure.
Mixing and Applying Mortar
Achieving the right mortar consistency is essential. It should be workable but not too wet because too much water can weaken the mortar. With proper application you’ll have good adhesion that fills all the joints completely. Techniques such as “buttering” bricks or stones—applying mortar to the sides before placing—help for a stronger bond between units.
Finishing and Texturing
Mortar joint’s finish can affect the overall appearance. Texturing techniques can be applied to concrete surfaces for decorative purposes. Finishing touches, like striking joints with a jointer, improve appearance while also adding to the overall weather resistance of the structure.
Maintaining Masonry Structures
Regular maintenance is important for preserving the beauty and integrity of masonry work. Proper care, like inspections and cleaning, can extend the lifespan of masonry structures and prevent costly repairs.
Regular Inspections
Inspections can identify issues early on, preventing minor problems from becoming major repairs. You should look for cracks, loose units, and signs of water damage. Checking for weeds growing between blocks also helps prevent structural damage.
Cleaning Methods
Gentle cleaning can keep masonry looking its best. Low-pressure washing or soft brushing are appropriate cleaning methods, as harsh chemicals can damage the masonry surface. Regular cleaning also prevents the buildup of moss or algae, which can hold moisture and deteriorate masonry over time.
Masonry: Our Conclusion
Masonry is a functional and unique construction method. Whether you’re a DIYer wanting to tackle a small project or a homeowner wishing to understand the work of professionals, this guide provides the knowledge to find a good pro or tackle a new project.
