Pro Masonry Guide April/May 2018 - Leslie Proctor, Art Director

PRO MASONRY GUIDE

Español a la vuelta

®

APRIL-MAY 2018

SAFETY THROUGH MASONRY

IN THIS ISSUE: MASONRY ESTIMATING WORKFORCE DEVELOPMENT REPAIRING SPALLED BRICK ProMasonryGuide.com

LVL

16’ -

Solid Sawn DI65 OSHA Pine

$33.90

16’ -

$27.99

Now the true one-call provider of

Scaffold Planks & Frames Walkthru Sets As low as

$99.00

5’ x 5’ Sets As low as

$84.00

866-900-0983

APRIL-MAY 2018

7 Making Buildings Safer

PRO MASONRY GUIDE

Through Masonry

®

Tornado season underscores the importance of reinforced masonry wall systems.

APRIL-MAY 2018

SAFETY

12 Determining a Unit

THROUGH MASONRY

Price for Masonry

Most masons will likely need to figure real costs for work to be done.

Here’s how.

7

Español a la vuelta

IN THIS ISSUE: MASONRY ESTIMATING WORKFORCE DEVELOPMENT REPAIRING SPALLED BRICK ProMasonryGuide.com

14 Step by Step: Replacing

On The Cover

Spalled Bricks on a Chimney Guidance for repairing spalled bricks in a chimney

Image courtesy of General Shale

16 Mason Training: Building a Future, Brick by Brick

Johnathon Crouch has been a masonry apprentice for four years and is well on his way to completing his apprenticeship.

12

17 What I’ve Learned

Virginia-based mason Donald McCauley gives a first-hand account of masonry lessons learned along the way.

16

DEPARTMENTS AND COLUMNS 3 From the Editor 4 News and Updates 5 Trowel Talk 6 Product Spotlights

14 ProMasonryGuide.com

6

Pro Masonry Guide//APRIL-MAY 2018

1

NOTHING Without us, you have...

100% made and assembled in the USA

With nothing between metal lath and the structural wall, you’ve got nothing to allow moisture to drain and dry rapidly. LathNet® is the only proven solution that combines standard U.S.-made metal lath and a drainage mesh in one factory-assembled panel. It’s easy to install, reduces labor time and costs, and cuts wall penetrations by up to 50%.

Get something for nothing. Get LathNet. Watch this and other proven solutions here: mortarnet.com/videos

Call or email for samples: 800.664.6638 x509 • samples@mortarnet.com

Your Reputation.

Your Legacy.

Our Mission.

FROMTHEEDITOR

>>

The Lasting Legacy of Masonry

I

’ve been an editor in the masonry industry for nearly 12 years, but my history with masonry far exceeds that time frame.

My late-father owned a brick distribution company serving south Georgia and north Florida, so I have felt comfortable around pallets of brick my entire life. I also developed the skill of recognizing a brick color, manufacturer and size, along with the color of mortar used to hold those bricks together, on virtually any house in my home town of Albany, Ga. When my parents decided to sell their hot tub and brick out their patio, I knew the project would turn out well.

The 4-foot-tall chiminea they’d used for nights around the fire was passed along, and a large, beautiful, stacked-stone chimney was erected.

For about a year, my dad was able to enjoy

For questions or comments, contact Pro Masonry Guide at 951.262.3688 or info@SilverLakeMediaGroup.com Publisher Kevin Kilpatrick, 770.615.3585 or Kilpatrick@SilverLakeMediaGroup.com

nights spent sitting by a fire roaring from the new chimney. He loved it, and when I visit my mother today, I sit and enjoy the fire. It’s become a special time when I can still feel my dad’s presence. And for many years to come, our family will enjoy fires by the patio chimney. It is a legacy my father left, whether or not he knew he was doing it at the time.

Over the years, I’ve talked to hundreds of masons who always say the same thing: They love that they can drive by what they’ve built and see that, years later, it’s still standing. Strong, proud, sturdy, and permanent. What they do matters and remains for decades to come.

After spring turns to summer, and summer becomes fall, I hope you’re able to enjoy a roaring fire of your own from a long-lasting chimney. I know I and my family will.

Sincerely,

Jennifer A. Morrell

Executive Editor Jennifer Morrell, 770.402.7142 or JMorrell@SilverLakeMediaGroup.com Vice President of Business Operations and Marketing Beth Wills, 678.662.6703 or Beth@SilverLakeMediaGroup.com Art Director Leslie Proctor, ArtDirector@SilverLakeMediaGroup.com For editorial opportunities, contact Jennifer Morrell, Executive Editor, at 770.402.7142 or JMorrell@SilverLakeMediaGroup.com For advertising opportunities, contact Dan Tomkiewicz at 770-640-1681 or Dan@SilverLakeMediaGroup.com Silver Lake Media Group 3162 Johnson Ferry Road, Suite 260-943, Marietta, GA 30062 ©2018 Silver Lake Media Group. All rights reserved. Pro Masonry Guide is published by Silver Lake Media Group, LLC, and The Cloud Peak Firm.

Notes to the reader: Due to differing conditions, tools and individual skills, Silver Lake Media Group and The Cloud Peak Firm assume no responsibility for any damages, injuries suffered or losses incurred as the result of following the information published in this magazine. Before beginning any work, review all instructions carefully, and if any doubts or questions remain, consult local experts or authorities. Because codes and regulations vary across the country, check with local authorities to ensure the work complies with all current codes and regulations. Always read and observe all safety precautions provided by manufacturers of any tools, equipment or supplies, and follow all accepted safety procedures.

Jennifer A. Morrell is an editor, journalist and publishing veteran with more than 20 years of experience. She has spent more than 15 years covering the areas of construction and development.

Contact Jennifer with your questions or comments at JMorrell@SilverLakeMediaGroup.com.

Pro Masonry Guide//APRIL-MAY 2018

3

NEWS &

UPDATES DAVID CHAVEZ WINS SPEC MIX BRICKLAYER 500 // In January, the 2018 World of Concrete trade show in Las Vegas was home to another successful BRICKLAYER 500 competition. The competition hosted 28 bricklayer and mason tender teams who raced against a 60-minute clock to build a 26foot x 8-inch double-wythe brick wall. The bricklayers’ walls were judged by 30 highly experienced masonry experts, enforcing 10 sets of craftsmanship requirements. This year’s winner was David Chavez, who achieved first place with the help of his friend and mason tender, Miguel Contreras, of Houston, Texas-based Ranch Masonry. Chavez won a total purse of more than $125,000 in cash and prizes, including a Ford F-250 4x4 XLT Super Duty truck and a John Deere UVX835 Crossover Utility Vehicle.

The BRICKLAYER 500 wasn’t the only noteworthy competition during Masonry Madness. The Spec Mix Toughest Tender Competition winner was Nicholas Miller with Brock Construction, who demonstrated a combination of speed and detail that required him to strategically lift, carry and place thousands of pounds of materials and tools needed to set up the bricklayer’s defined workstation. The Spec Mix Top Craftsman Award was won by bricklayer Leif Reints with Reints Masonry in Wyandotte, Okla., with the help of mason tender Michael Weisinger, who together boasted 625 perfectly laid bricks.

BRICKLAYER DAVID CHAVEZ (LEFT) AND HIS MASON TENDER, MIGUEL CONTRERAS (RIGHT), CELEBRATE WINNING THE 2018 SPEC MIX BRICKLAYER 500 WORLD CHAMPIONSHIP.

CONSTRUCTION SPENDING ON THE RISE

NATURAL STONE INSTITUTE ANNOUNCES 2017 PINNACLE AWARD WINNERS

// Construction spending in January was unchanged from December and was moderately higher than in January 2017, according to an analysis of new government data by the Associated General Contractors of America (AGC). Construction spending in January essentially matched the upwardly revised December record level of $1.263 trillion at a seasonally adjusted annual rate. The January total exceeded the year-earlier level by 3.2 percent.

For the month, private nonresidential construction spending rose 0.3 percent, private residential spending declined 1.5 percent, and public construction spending gained 1.8 percent. On a year-over-year basis, private residential construction spending increased 4.2 percent, private nonresidential spending slipped 1.1 percent, and public construction spending jumped 8.2 percent, says the AGC.

// The winners of the 2017 Pinnacle Awards were announced at the Natural Stone Institute Awards Ceremony recently in Las Vegas. For the 10th year, a Grande Pinnacle Award was presented to the best overall project. The 2017 Grande Pinnacle Award was presented to Bronx, N.Y.-based Port Morris Tile & Marble for their work on the 520 W 28th Street Lobby Feature Wall in New York City.

Eleven Pinnacle Awards of Excellence were bestowed during the ceremony. The Commercial Interior winners were Euromarble of Carrara, Italy; Camarata Masonry Systems Ltd. of Houston, Texas; and Masonry Pte. Ltd. of Singapore. The Commercial Exterior winners were ROCAMAT Pierre Naturelle of L’Ile-Saint Denis, France; Coldspring of Cold Spring, Minn. (winner of two awards); and ABC Worldwide Stone LLC of Brooklyn, N.Y. The Residential award winners were 3D Stone Inc. of Bloomington, Ind., and Stones and Roses International Co. Ltd. of Samutprakarn, Thailand. The Renovation/ Restoration winners were Marmi Natural Stone of Norcross, Ga., and H E FILIPE PEREIRA WITH ZAHA HADID ARCHITECTS, COLIN ADDLEY WITH PORT Satterwhite of Richmond, MORRIS TILE & MARBLE, AND CHIARA DE LUCA WITH MARMOMAC, ARE SHOWN Va. WITH 2017 BSI PRESIDENT DANIEL WOOD AND 2017 MIA PRESIDENT JON LANCTO.

4

APRIL-MAY 2018//Pro Masonry Guide

ProMasonryGuide.com

TROWEL

TALK

Spreading the Word About Masonry

By Paul Cantarella

A

few weeks ago, I got a message from a former neighbor who lived a few streets away when we were growing up.

Sometimes, when I see that out-of-town area code appear that late in the day on my work cell phone, I know there’s a 50-50 shot it’s a salesman. I rolled the dice, and I didn’t answer.

This friend was calling to ask for my help in showing his son what real work with your hands was all about. He said his son is 21 years old and has decided that college is not the path that he wants to take. As any caring parent would, he wants to get him out there in the real world so he can see what being in a trade would be like. He seemed to be at a crossroads regarding how he could give his son a taste of the construction industry.

After listening to the message, I sat in my office wondering how I could help. The more I thought about it, the more I realized I had no good answer for him. This really got my mind spinning. How do you expose someone to the masonry trade?

All the construction projects that we work on require workers to have OSHA 10 cards.

And most insurance companies probably would hesitate if you called and asked if the guest worker would be covered under your insurance in case something happened.

Trying to get someone on a jobsite just to

ProMasonryGuide.com

walk around is not an easy task. Another option would be to sign the person up for the BAC apprentice school, but that’s a major commitment to something without ever trying it.

Last year, we held our first job fair. We were nervous and didn’t know how it would go. We brought one of our young masons who had just finished his apprenticeship and was already working his way up the ladder with us. We set up a little bench, mixed up some mortar and let the kids lay some bricks.

To our surprise, many kids tried laying a few bricks. This really opened my eyes to the notion that there is no exposure of our trade to the younger generation. The sad part is that we really need to get to the kids at a younger age. I felt the younger group of kids seemed more interested in talking about things they could do when they get out of school. The majority of high school seniors, at that point, probably had made up their minds about the paths they were taking. I think most of us are realizing this and are trying to get the kids involved at a younger age.

We are thinking of adding another job fair this year. We have enough on our plates, but if no one does anything, we will not have the workers to keep our doors open. I have heard some contractors talk about adopting

a vocational school and trying to hold a class. This seems like another great idea that we are looking into.

I also know that I could do a better job promoting the trade. I used to use the saying, “I am only a dumb mason.” It was my father’s line when I was growing up when someone would ask him a question unrelated to masonry but wanted his input.

Needless to say, I have wiped that saying out of my head.

It’s been three weeks since the call and I still don’t have an answer that I am happy with. My best reply will be to go down to the local masonry supply company and get some of the names off the board (most places have business cards of local masons for potential customers) and try to get their hands dirty that way. Then, they can decide if this is a route they would like to take in life. On my end, I need to figure out how I can close the loophole so that potential craftspeople can be exposed to our trade easier. Line up and safety always.

Paul Cantarella Jr. is president of Cantarella & Son Inc./Corporate Secretary C&S Co. Inc. and vice president of East Coast Air Barrier & Restoration, based in Pittsfield, Massachusetts.

He also is the MCAA Massachusetts State Chairman and a member of the South of 40 and the Safety committees.

Pro Masonry Guide//APRIL-MAY 2018

5

PRODUCT

SPOTLIGHTS Concrete Groover This durable, fully forged masonry trowel features a solid shank through handle design. Forged from a single piece of high-carbon steel for extra strength, this trowel also has flexible taper ground blades to minimize surface gauging and accidental marks often left by new trowels. It’s corrosion resistant and easy to clean.

homedepot.com/p/ RIDGID-6in-x-4-3-8inZinc-Groover-w-1in-BitCM6000/301616258

Advanced Polymer Sealant Adhesives A solvent- and isocyanate-free line of high-performance, commercial-grade flexible repair and bonding materials, Quikrete Advanced Polymer Adhesives meet ASTM C920 standards.

Designed to deliver or exceed the performance of traditional polyurethane or silicone sealants and adhesives, the single-component adhesives are environmentally friendly alternatives.

Available in 10-ounce tubes, the Quikrete Advanced Polymer Adhesives are applied with a high-quality caulk gun. Included are a Self-Leveling Sealant, a Mortar Joint Sealant, a Concrete Crack Sealant, a Construction Adhesive, and a Non-Sag Sealant.

Marble Looks in New Colors Architectural Services Group has released an expanded color palette for its high-end MetroQuartz offering.

Brochures showcase full slab images for veined marble looks, and the MetroQuartz website features full slab images plus installation photos for every color. Atlantis is made to resemble concrete, with more variation in both color and texture than a typical quartz slab. All colors are available in both 2- and 3-cm thicknesses and combine durability with long-lasting performance.

MetroQuartz.com

Quikrete.com

6

High-Resolution Aerial Imagery and Maps Nearmap manages and delivers current location content, allowing contractors, engineers and architects to unlock opportunities that consistently improve decision-making and transform the way they work.

The company offers high-resolution aerial imagery as a service, including orthographic (vertical) maps, multiperspective panoramas and oblique aerial views. Nearmap Oblique and Nearmap Panorama allow users to visualize, monitor, navigate and measure sites in a 3-D perspective from all cardinal directions. This is all instantly accessible and is 100 percent cloud-based.

Go.Nearmap.com

Cordless Rotary Hammer

Lithium-Ion Powered Cut-Off Machine

Wet Cutting Masonry Saw

Cordless Tire Inflator

The Hilti cordless rotary hammer TE 6-A36 has a brushless drive, offering outstanding power-to-weight ratio, and featuring a high runtime flexibility. It has two compatible 36V batteries, the B36/2.6 CPC Li-Ion compact and the B36/5.2 CPC Li-Ion Industrial. In addition to its superior performance, the TE 6-A36 is compatible with Hilti’s new DRS6-A (T1) OSHA 1926.1153 Table 1-compliant integrated dust removal system. The DRS-6-A offers a builtin motor for 100 percent suction power from the beginning of use.

STIHL’s battery-powered TSA 230 STIHL Cutquik cut-off machine delivers maneuverability and solid cutting performance in a lightweight, compact package. With zero-exhaust emissions, the TSA 230 enables indoor cutting in enclosed spaces and other jobsites where users are not permitted to use traditional gasoline-powered cut-off machines. Wet cutting is made easier with onboard water connection and control, which suppresses dust. The cut-off machine is fueled by a low-maintenance, brushless, commercialgrade high torque electric motor, creating little noise.

MK Diamond addresses the new ruling

by OSHA for silica dust reduction by redesigning the BX-3 Masonry Saw to include a wet cutting model. The BX-3 targets the mason contractor's needs for portability, durability and reliability.

Designed for light weight and versatility, the BX-3 weighs only 50 pounds and features a high-torque motor capable of cutting a variety of masonry material, such as brick, stone, pavement and concrete block. With a 1 ¾-horsepower, 120-volt motor offering a blade RPM of 3,500, the BX-3 delivers on job performance and reliability.

Milwaukee Tool’s M12 Compact Inflator is a cordless tire inflator capable of completing demanding inflation applications such as LT truck tires. It delivers fast, accurate, easy inflation with the portability to take anywhere. Rated to deliver more than 120 PSI and built with a high-efficiency motor and pump, the M12 Compact Inflator delivers up to 5X the speed of fill on light truck tires and can fill a light truck tire from flat to full on a single battery.

Hilti.com

STIHLusa.com

MKDiamond.com

APRIL-MAY 2018//Pro 2018 //Pro Masonry Masonry Guide Guide

MilwaukeeTool.com

ProMasonryGuide.com

SAFETY

>>

Making Buildings Safer Through Masonry Tornado season underscores the importance of reinforced masonry wall systems.

By Dawn Henning

T

ornado season typically peaks in April through June. But in January 2017, violent outbursts struck, featuring one of the largest tornado events to ever occur in winter. A spate of storms produced 79 confirmed tornadoes across the Deep South from Texas to South Carolina, resulting in the second-deadliest January outbreak on record.

According to the National Oceanic and Atmospheric Administration (NOAA), the United States averages more than 1,000 tornadoes per year – more than any other country. Annual insurance losses from U.S. tornadoes and thunderstorms range in the billions of dollars. The costliest event occurred in Tuscaloosa, Alabama, and nearby areas, in April 2011, totaling $7.8 billion in insured damages.

Although events of this magnitude account for only a small percentage of the total number of tornadoes that occur in the United States, the Tuscaloosa event Reinforced masonry that is adequately connected to other building components can withstand high wind loads, – along with the tornado that struck Joplin, Missouri, offering greater protection against wind-blown debris. a month later – initiated an ongoing review of building standards and closer scrutiny of materials used in new a continuous load path and decreases wind force vulnerability. construction. It was determined that older homes are susceptible Openings, such as windows and doors, including garage doors, are to tornado damage, but improved building standards can help save strengthened. This reduces the potential for pressurization, which many new structures from destruction, thereby saving lives during can occur inside a building when these openings are compromised future tornado activity. by wind damage. Pressurization can result in significant damage to In addition, since 2011, further study of a tornado’s path has or total destruction of a building. indicated that greater damage occurs at the center of a tornado, with far less severe damage being inflicted on structures located near the How masonry can help edge. Even in the event of a rare EF-5 tornado, the greatest damage Reinforced masonry that is adequately connected to other building is limited to a narrow path, and most structures don’t experience a components can withstand high wind loads. It also offers greater tornado’s highest wind speeds. All of this is good news, since the protection against wind-blown debris, which can penetrate a majority of U.S. tornadoes are EF-2-level storms or lower. building’s cladding and leave the structure at greater risk for internal Improved building practices for tornado-resilient structures pressurization. According to the Brick Industry Association, testing include correct construction for load transfer, along with proper performed at Texas Tech University’s Wind Science and Research connections between the roof, walls and foundation. This creates

ProMasonryGuide.com

Pro Masonry Guide//APRIL-MAY 2018

7

XP500 THIN VENEER ADHESION MORTAR THE MIX WITH GRIP! THE MASONS ACROSS NORTH AMERICA TOLD US WHAT THEY NEEDED—WE DELIVERED! SPEC MIX® Thin Veneer Adhesion Mortar XP500 is a thin set adhesive designed specifically for masonry craftsmen. SPEC MIX XP500 is a stand-alone cementitious product engineered to adhere thin cut natural stone and manufactured masonry veneer units. Formulated with high performance additives that mitigate sagging, maximize jobsite productivity and yield shear bond strengths that exceed the requirements of ANSI 118.15.

XP500 is THE MIX you’ve been waiting for!

CALL YOUR SPEC MIX DISTRIBUTOR TODAY

WWW.SPECMIX.COM

© 2018 SPEC MIX

APRIL-MAY 2018 //Pro Masonry Guide

SAFETY

“

ACCORDING TO THE BRICK INDUSTRY ASSOCIATION, TESTING PERFORMED AT TEXAS TECH UNIVERSITY’S WIND SCIENCE AND RESEARCH CENTER CONCLUDED THAT BRICK STRUCTURES OFFER A MUCH HIGHER DEGREE OF PROTECTION FROM WIND-BLOWN DEBRIS THAN DO BUILDINGS CONSTRUCTED WITH OTHER FORMS OF CLADDING.

”

Center concluded that brick structures offer a much higher degree of protection from wind-blown debris than do buildings constructed with other forms of cladding.

One option for safer cladding is an oversized structural brick that is manufactured by General Shale, the Endurance RS4 structural brick. The company says the RS4 is designed to withstand strong winds and its oversized design yields safe, strong, sustainable and energy-efficient construction. “RS4” is an acronym representing Real Strong, Real Safe, Real Sustainable, Real Smart. General Shale says the Endurance brick is designed to bear higher loads, meet seismic requirements, and offer resistance, which can be reassuring

ProMasonryGuide.com

>>

Shown is the Endurance RS4 structural brick, an oversized structural brick manufactured by General Shale.

for builders and homeowners in areas susceptible to high winds and tornadic events. These include commercial or government buildings such as hospitals, schools, courthouses and police stations.

Larger engineering and utility-size bricks have been used for reinforced masonry applications for many years. The Endurance RS4 uses this same proven engineering method, but can be installed with minimal labor and overall cost adjustments. This is a key benefit for builders, architects and contractors who need easy-to-install, efficient and cost-effective building solutions.

Endurance wall systems can also be used in conjunction with any type of interior wall construction (e.g., furring strips, non-load-bearing

Pro Masonry Guide//APRIL-MAY 2018

9

™

KNOW-HOW

RIGHT PRODUCT FOR EVERY PROJECT.

FINISH STRONG.

10

SAKRETE.COM

When your professional know-how is backed by the consistent quality of Sakrete, your projects will hold stronger and last longer. Every project.

Every time. Go online to view Sakrete retailers near you or get your project started with our easy-to-use concrete calculator.

APRIL-MAY 2018 //Pro Masonry Guide

© COPYRIGHT 2018. ALL RIGHTS RESERVED.

ProMasonryGuide.com

SAFETY

>>

metal studs, hat channel, etc.) and insulation systems. The use of continuous rigid insulation, which reduces thermal bridging, is one of the most efficient methods of construction, both in terms of costs and energy savings. The combination of the Endurance RS4 and continuous insulation helps increase a building’s energy efficiency and can lower a structure’s Home Energy Rating System score.

Bottom line, the combination of Endurance RS4 structural brick with appropriate reinforcement between the wall system and roof creates a safe, strong and durable structure, providing greater peace of mind for property owners who live in areas at higher risk for significant weather events. pPMG

ProMasonryGuide.com

Pro Masonry Guide//APRIL-MAY 2018

11

MASONRY ESTIMATING

>>

Determining a Unit Price for Masonry Most masons will likely need to figure real costs for work to be done. Here’s how to determine a unit price for masonry.

By Steven Fechino

B

eing a mason contractor requires many skills. You have to estimate projects, maintain equipment, provide material and labor, and collect your money.

Estimating, for some masons, has become easy. When a project is set up to pay by unit price, you simply tell the contractor how many brick and block you will lay per amount. That is it. If the contractor pays a bit better for each task, it will include extras like quoins, arches and sills.

However, a time will likely come when a smaller mason will need to figure real costs to perform a task. Here is a basic example.

You need to build a brick and block wall that is 50 feet long x 8 feet tall. How many units will you install to build it? Well, by unit price, it may be as simple as $X.00 per thousand brick and $X.00 per concrete block. Do you know how many brick and block you will lay?

The area of the wall is 50 feet times 8 feet, which equals 400 square feet. The number of modular brick is 6.8 brick per square foot of wall (without extras). So, 400 square feet times 6.8 brick per square foot equals 2,720 modular brick.

Now, to calculate the concrete block (Concrete Masonry Unit or CMUs), there are 1.125 CMU per square foot of wall (without extras). Doing the math, 400 square feet times 1.125 CMU per square foot equals 450 CMU. The materials you install will be mostly on grade, but you will have to construct a hop board or a small scaffold to top out the coursing.

This will take a little time. Whether you use a hop board or scaffold, the 8-foot boards you could use generally only give you 7 feet of span due to end lapping.

For a 50-foot span, you will need: 50 feet divided by 7 feet, equaling 8 boards. Triple this for the double hop board and single material board, and you now are moving a minimum of 24 boards.

Keep in mind that, if you are using a scaffold, it would legally be 56 boards, two walk boards, and five material boards for each scaffold span. All of this material has to be on the truck, ready to be installed, before any materials can be laid.

APRIL-MAY 2018 //Pro Masonry Guide

How much wall wire is necessary, and how many wall ties do you need to install?

If you see that the wall is 12 courses tall, you can easily figure that the wall wire will be every other course. That would equal six levels of wall wire. Six levels times 50 feet per level will equal 300 linear feet of wire to be installed, or 30 pieces – almost a bundle.

Another way to figure this would be to take the square footage of the wall and divide it by 1.33, which would equal the same number. Let’s just say this is a small residential project and corrugated ties are going to be used. One method of figuring the ties is one tie for every 10 brick.

In this case, that would equal 272 ties, which is a small box of ties plus part of another box. Another way to figure this is to take the square footage of the wall and divide it by 1.45. That should give you an accurate number of ties.

Mortar for the CMU Mortar is the last part of the estimate to be covered here. Mortar can usually allow for about 140 brick per bag in the wall, and 35 CMUs per bag.

of mortar, equals 20 bags of mortar required to lay the wall. You will mix mud 10 times in a two bagger.

This simple wall that you quickly offer unit prices for includes roughly: ● ● 2,720 brick ● ● 450 CMU ● ● 30 pieces of wire ● ● 272 brick ties ● ● 24 walk boards, minimum ● ● 33 bags of mortar

There is a quick way to figure this: Here’s the math: 8 feet times 50 feet, times 1.125 CMU per square foot divided by 35 CMU per bag of mortar, equals 13 bags of mortar that will be required for this wall. You will mix mud seven times in a two bagger.

Mortar for the brick To estimate mortar for brick, here is the math: 8 feet times 50 feet, times 6.8 brick per square foot divided by 140 brick per bag

Now you can know exactly how much material you’ll install when you figure a small project.

Steven Fechino is engineering and construction manager for Mortar Net Solutions. Steven has 35 years of experience in masonry restoration, moisture management and hardscape construction.

GET RID OF WINTER GRIME With Restoration Cleaners From Diedrich 101 MASONRY RESTORER A powerful combination of acids and biodegradable detergents that penetrate, dissolves, and suspend dirt, grime, and carbon for easy removal of mildew, industrial pollutants, exhaust residue, and most stains.

ENVIRESTORE 100™ A blend of citric and phosphoric acid that gently cleans brick and stone while being safer for workers and the environment.

www.diedrichtechnologies.com ProMasonryGuide.com

Available in

1, 5, OR 55 GALLONS

toll free: 1-800-283-3888Pro Masonry Guide//APRIL-MAY 2018

13

REPAIRS AND RESTORATIONS

>>

Replacing Spalled Bricks on a Chimney Chimney bricks experience the wrath of all seasons, so replacing spalled bricks on a chimney is a worthy skill to have.

By Brian Estill

B

ricks are like sponges. We all know that.

So why do we think it’s not important to waterproof bricks with a sealant? Equally troublesome is the belief that masonry is maintenance free – it’s not. Replacing spalled bricks on a chimney is a part of maintenance. Bricks on a chimney take on the worst of all four seasons, so sealing your chimney should to take priority over the rest of your house.

With that being said, if a chimney has more than two or three spalled bricks, this problem needs to be addressed immediately. Let’s say you see a few courses of brick that are spalled. This is a sign that the chimey cap has gone bad and needs to be replaced.

Tools and Materials 1. Bricks (of course) 2. Mortar (of course) 3. Hammer drill 4. 5/8 masonry drill bit 5. Mixing paddle 6. Ladder 7. Mason’s trowel 8. ¼-inch tuck pointer 9. Jointer 10. Brush 11. Water sprayer 12. One-inch chisel 13. Shop vacuum and extension cord

Shown is a spalled brick in a chimney in need of repair.

Step 1 Set up your ladder. Assuming you can reach the bricks you’re replacing – and you don’t need another ladder or anything else 14

APRIL-MAY 2018 //Pro Masonry Guide

– let’s begin here. Use your drill and 5/8-inch masonry drill bit to drill two holes for the bricks in the middle of the wall, three holes for the bricks on the corners.

Use your one-inch chisel or hammer setting on your hammer drill to start crushing the brick. A tip for replacing spalling bricks is to begin above or below the holes. Removing the brick ought to be fairly easy. The leftover mortar on the other bricks is going to be a little more difficult.

Step 2 Use your one-inch chisel to tap on the leftover mortar on the other bricks. If the chisel doesn’t work that well, use a line pin. Try to tap between the brick and old mortar. If that still doesn’t work, sand the mortar out using sandpaper. Dry-fit the brick.

ProMasonryGuide.com

“

IF A CHIMNEY HAS MORE THAN TWO OR THREE SPALLED BRICKS, THIS PROBLEM NEEDS TO BE ADDRESSED IMMEDIATELY.

Step 3

”

Use your cordless drill or a small square trowel to mix up your premixed mortar in a five-gallon bucket. Remember a little water goes a long way, so assure your mortar is kind of dry. Now stick your trowel, jointer, soft brush, and tuck pointers in the bucket. You’re ready to lay brick.

Step 4 Use your water sprayer to mist the hole where you’re putting the brick. This allows for a good bond. Butter your brick, and then butter the hole the brick is going into. Slide the brick into the hole. Look at the bricks to the right and left. Is it close to being in the middle of those bricks on either side? Good, those are your head joints.

How about the bricks on the bottom? Is it parallel with those bricks? Great, that’s your bed joint. Now, use your tuck pointer to tuck point the top joint and pack the mortar all around the brick. Is the mortar thumbprint hard yet? Then let’s joint it, brush it, and joint it again.

Shown is the finished, repaired chimney brick.

You’re finished replacing spalled bricks on a chimney. Wait a couple days, and then come back with some waterproofing sealer, a paint brush and a paint roller to waterproof the chimney.

Brian Estill is a brick mason and masonry artisan in Louisville, Ky.

Step 5 Time to clean up your area. Use your brush and trowel to sweep up the loose bricks and old mortar. Put everything in your bucket. Take the bucket down, and then bring up your shop vac and vacuum up the remaining dust. If you can get a hose up there, hose the roof down after you’re done.

The spalled chimney brick is in need of repair.

ProMasonryGuide.com

Pro Masonry Guide//APRIL-MAY 2018

15

WORKFORCE DEVELOPMENT

>>

Masonry Training Programs: Building a Future Johnathon Crouch applied for one of the masonry training programs four years ago and is well on his way to completing his apprenticeship.

By James Lally

A

t 17, Johnathon Crouch enlisted Guard. His union also offers apprentices a in the Connecticut Army Nachance to earn benefits such as healthcare and tional Guard as an infantryman. retirement.

It was 2012, and in the summer “If you are looking to learn a trade and you between his junior and senior years of high don’t mind working hard, then this is a trade school he left to attend U.S. Army Basic Comworth learning,” Crouch says. “It’s very rewarding bat Training at Fort Benning in Georgia. After to see your work put into a project and knowing graduating high school, he returned to Fort you did this or that. The money isn’t bad and my Benning to complete infantryman training, and annuity adds up quick. It’s nice to have if you then he returned to Plainfield, Conn. He was need it for a hardship or down payment on a ready for the next chapter of his life. house.”

Crouch applied for one of the masonry As an apprentice, Crouch has learned to training programs with the Bricklayers & install a wide variety of masonry materials, such Allied Craftworkers Local 1 CT. A week after as brick, block, stone, precast and concrete, acceptance, his classes began. Now 22, Crouch as well as how to use the common tools has been an apprentice for four years. He and machinery that go with the job. He also works for Joe Capasso Mason Enterprises understands the importance of on-the-job safety. in Middletown, and he is well on his way to His work training included OSHA’s 10-Hour Johnathon Crouch, a masonry apprentice with a Connecticut completing his apprenticeship. His determination Construction Course, along with courses on how bricklayers’ union, builds a wall as part of his training. is evident. to erect scaffolds and use suspended scaffold “Once you start something, never give up – and scissor lifts. finish it,” Crouch says. “No matter how tired, sore or frustrated you become, “I feel that learning to maintain high standards holds me accountable for just keep going. It’s all temporary, and the further you come along through the quality of my work and basically the integrity of a building,” Crouch says. your apprenticeship, the better it gets. Pay your dues and before you know Registered Apprenticeship is a training system that offers masonry it, you’ll be moving up the ladder.” training programs and produces highly skilled workers to meet the The U.S. Department of Labor’s Registered Apprenticeship program demands of employers competing in a global economy. A proven strategy, allows employers, unions, community colleges and universities, workforce Registered Apprenticeship ensures quality training by combining on-theinvestment boards, industry associations and the military to sponsor job training with theoretical and practical classroom instruction to prepare apprenticeships and register them with the department. Apprentice exceptional workers for American industry. program sponsors may certify an apprentice is participating to enable You can learn about Registered Apprenticeships in your area at https:// veterans and service members to use the education benefits they earned oa.doleta.gov/bat.cfm. while in service.

James Lally is deputy director in the U.S. Department of Labor’s Apprentices do not qualify for a mason’s full rate of pay until they are Office of Public Affairs in Boston. This article first appeared April 5, fully trained, but Crouch was able to supplement his income using the 2017, in the U.S. Department of Labor Blog.

Post-9/11 GI Bill, an education benefit he earned while in the National 16

APRIL-MAY 2018 //Pro Masonry Guide

ProMasonryGuide.com

WHAT I'VE LEARNED

>>

Don't Be Afraid to Take a Chance Donald E. McCauley, Jr.

D

o you ever get so caught up with life that you feel like you just ended up where you are without realizing what you did to get there? One of the biggest things I have learned is not to be afraid to take a chance or to cut against the grain of what other people think is right for your life. It’s ok to take a different path, even if you have to sacrifice in the short term for long-term gain.

Back in the mid-80s, I was making top dollar as a bricklayer at $19 per hour. Out of the blue, I was offered an entry-level estimating position by the owner of the company where I worked. It was a great opportunity, but it came with a caveat. The starting salary was only $10 per hour with no benefits. This was a heavy decision, since I had just gotten married. This decision would change the trajectory of my life, one way or another.

After much reflection and praying, I decided to take a chance and go for it. I soon learned that if you have a solid work ethic, aren't afraid to put in the time, keep an open mind, and are ready to learn something every day, you can rise to the top. One thing led to another and after about five years, I had become a senior estimator making three times what I did as a top-dollar mason. Five years after that, I became a senior project manager/ senior estimator, making well into a six-digit income. Finally, seven years ago, my wife and I started our own masonry company. This all became possible because I learned a trade.

ProMasonryGuide.com

“

I HAVE SEEN SO MANY PEOPLE END UP TOTALLY MISERABLE BECAUSE THEY DID WHAT OTHERS TOLD THEM TO DO AND WEREN’T TRUE TO THEMSELVES.

”

Instead of going the traditional route and doing what every teacher, every guidance counselor and even my parents were pushing me toward—attending college—I found my own path. I was told that college was the only way I would have a future, but all I saw was a waste of four years and tremendous debt that would be racked up for a career in whatever it may have been.

College isn't a one-size-fits-all. I believe we need more diversity in our education system to allow for on-the-job training. This is offered through trade and vo-tech schools.

The challenge is the overall attitude that school counselors, society, peers and parents have toward these schools. The perception is that attending one of these schools means you aren't smart and are somehow a lowerclass citizen because you get your hands dirty. This perception needs to change.

I am, by no means, advocating that a college education is worthless. It just isn't meant for everyone. My wife and I have six children and we are raising them to understand who they are and to make choices about their futures based on their passions in life. I would be honored if one of my children decided to learn my trade and follow in my footsteps for a third generation, but I make it clear to them that they aren’t obligated. What really brings a person success is being driven and passionate about whatever he or she does in life. If a person can keep these character traits as a nucleus to fall upon, then tough choices can be made regarding the right path to take in life—trade school, college, spouse, family and career. I have seen so many people end up totally miserable because they did what others told them to do and weren’t true to themselves.

Even when a trade school is chosen, I would recommend supplementing that experience with educational classes that work hand-in-hand with your trade. No matter what you chose as your career path, always stay true to yourself. Stay humble and remember where you came from and learn something new every day.

My grandfather once told me when I was a young man that if I was on the train tracks of life, and I was out in front of everyone else and decided to slow down and enjoy where I was, I would get run over by someone who didn't take his foot off the gas. So keep your foot on the gas and don’t be afraid to take a chance. p PMG Pro Masonry Guide//APRIL-MAY 2018

17

INTERESTED IN PASSING ON YOUR KNOWLEDGE AND EARNING SOME EXTRA DOUGH?

If so, Pro Masonry Guide is looking for you. Pro Masonry Guide is adding to our team of technical advisors.

An advisor may be called upon to discuss or review an article, or may be asked to test a tool or building supply product. The advisor position is not a full-time commitment, and you would not have to quit your current job.

Pro Masonry Guide only hires the most knowledgeable tradesmen. To be considered, simply visit ProMasonryGuide.com/advisor, fill out the contact information and take a short quiz.

That’s it. If your score is high enough, you will be eligible to be a new Pro Masonry Guide technical advisor.

3 Easy steps to become an advisor.

1

GO TO ProMasonryGuide.com/advisor

2

ENTER CONTACT INFORMATION

3

TAKE A SHORT QUIZ TO PROVE YOU KNOW YOUR STUFF

PROMASONRY GUIDE 18

APRIL-MAY 2018 //Pro Masonry Guide

ProMasonryGuide.com