All masonry walls will rest on a foundation, footers or
concrete slab. Prior to erecting a block or brick wall, the foundation
must be clean so the mortar will adhere to it. It should also be
relatively level.

If you are building a wall for a home addition, garage or
other structure, it is important to be able to read construction
drawings to identify all the dimensions for the walls which are
given on the floor plan and elevation. The walls are to be laid
out the same as on the floor plan, with all measurements followed
exactly. The openings for doors and windows must be placed exactly.
It is important that the corners be set on the foundation exactly
as given on the detail drawing on the foundation plan. Taking measurements
from the foundation or floor plan, and transferring those measurements
to the foundation, footing or floor slab is the first step in laying
out the wall.
Once
two points of measurement are established, either corner to corner,
or corner to door opening, a chalk line will be marked on the
surface of the foundation. This chalk line will establish the
line to which the face of the block or brick will be laid. Since
chalk can wash away, a grease crayon or a nail can mark the surface
for key points along the chalk line, so that the chalk line can
be re-snapped along these markings as needed.
After
the entire surface is marked
as to where the wall is to
be laid, where the openings
are located and where the
control joints are located,
a final check should be made
against the foundation or
floor plans.
Starting
with the corners of the wall,
lay the first course or level
of block without mortar,
so a visual check can be
made between the dimensions
on the floor plan and how
the first course actually
fits the plan. This dry run
will tell you which block
will need to be cut to fit
openings, etc. During the
dry run, block units will
be strung along the entire
width and length of the foundation,
floor slab and even across
openings. This will show
how bond will be maintained
above the openings. Since
all mortar joints should
be 3/8", the dry run of block
will be spaced accordingly.
This can be simplified by
using a 3/8" piece of wood
placed between block as they
are laid during this dry
run.
Once
this is done and there are
no problems, use a steel
square to mark the exact
location and angle of the
corners. It is essential
that the corner be built
as shown on the floor or
foundation plan. The wall
plan has probably been designed
according to a modular dimension,
which means that no block
will have to be cut. Building
the corners as specified
is key to maintaining modular
dimensions.
Building
exact corners is the most important construction
of a masonry
wall as corners will guide the building of the rest of the wall.
A corner pole will make the job easier. A corner pole is any type
of post which can be braced into a true vertical position and which
will hold a taut mason's line without bending. Two such poles are
set up, one on each corner, with the mason's line stretched between
them. Corner poles for block walls should be marked every 4 to
8 inches, depending on how high the material is with which you
are building the wall. Such marks must be absolutely level when
the mason's line is stretched between them.
Now the first course is ready
to be laid in mortar. About 1" thick mortar is spread, full bed,
on the foundation or slab. The only exception to spreading a
full bed of mortar at the first course is where reinforcing rods
or steel rebar are projecting from the foundation footing or
slab. Since the cells of the block where these rods will be located
will be grouted, no reason for a full bed of mortar. In such
cases where rebar or rods are used, leave a space around the
rods so that the block will be seated in mortar, but the mortar
will not cover that part of the foundation.
Next,
using a mortar board, it's time to lay the
mortar. Picking up a small amount of mortar
with the trowel, the trowel point is placed
on the foundation. Rotate the trowel 180 degrees,
moving the trowel in a backwards motion in
the direction you want to lay the mortar. The
mortar should slide off the trowel with ease.
It is the rotating and backward motion simultaneously
that will release the mortar from the trowel.
After spreading
a full bed of mortar on the marked foundation,
the first block of the corner is carefully
positioned with the marked lines in both directions.
Press the block down until a 3/8" joint is
made. If necessary, tap the top of the block
lightly, usually with the handle of the trowel,
to get the block into proper alignment. It
is essential that the first level or course
of block is plumb (straight up and down) and
level.
Once the corner
blocks are placed, the lead blocks are set.
This will entail about three or four blocks
going from each side of the corner. When laying
block against one already in place, you will
trowel a vertical bead of mortar along the
side of the block, creating a head joint (mortar
placed along the block vertically). Press or
shove the block gently against the one already
in place. This shove will help make a tighter
fit of the head joint. But the shove must not
be so strong as to move the block already in
place.
Corners and
lead blocks are generally built 4-6 rows high,
with each course being stepped back one block
from the course below, creating a pyramid effect.
The wall alignment, plumb and level should
be checked on these corners before completing
the wall. If everything checks out fine, it
is now time to fill in each course between
the corners. Make sure the mason's line is
stretched taut and attached to the line holder
at each corner. The line should be no further
away than 1/8" from the face of the wall, and
when the block is set into the mortar to form
a 3/8" mortar joint, the top of the block should
be even with top of the mason's line. Allowing
the block to touch the mason's line is called "crowding
the line" and could cause a bulge in the wall.
The first course of block
is laid from corner to corner, allowing for openings or doorways.
It is important that mortar for these blocks is spread on all
vertical edges of the block before the block is carefully put
in place. When laying the second row or course of block (and
all rows above), mortar must also be placed on block directly
beneath the block to be laid (
Please
click here for instructions on how to place mortar on the block)
It is also
important that for each course, block should
not be stacked directly on top of the block
below, rather, it should be staggered so the
block being laid is placed half over one block
below, and half over the other block below.
Otherwise, a weak spot will be created within
the wall.
As
each block is put into place, the mortar which
is squeezed out should be cut off with the
edge of the trowel and care should be taken
that the mortar doesn't fall off the trowel
onto the wall or smear the block as the excess
mortar is being removed. When building block
walls, it is important to press firmly so that
a good bond forms between the mortar and the
block. Once dry, the mortar can be flicked
off with the trowel. If there should be some
stain on the face of the block, it can be rubbed
off with a piece of broken block or brick,
or brushed off with a stiff bristle brush.
All squeezed
mortar which is cut from the mortar joints
can either be thrown back onto the mortar board
or used to butter the next block. Mortar which
has fallen onto the ground should not be salvaged.
The work of
building the corners, stringing the line, laying
the course between corners, will continue until
you reach the next to last course. At this
point, you will know whether a masonry wall
cap or coping will be placed on top of the
last course or if the top course will be filled
with mortar and another type of coping placed
on the top of the wall. If mortar is to go
into the cells of the top course of block,
a wire mesh has to be placed across the cells
of the block below so that the mortar in top
course will be held in place.

| 1. |
Put a straightedge on the
top course to assure that a level has
been built. |
| 2. |
Use the straightedge across
the face of the wall to be sure that
it is plumb and aligned. |
| 3. |
Make sure all mortar joints
are cut flush with the wall, awaiting
tooling. |
| 4. |
Check to see that there
are no pinholes or gaps in the mortar
joints. If there are, and if the mortar
has not yet taken its first set, these
mortar joint defects should be repaired
with fresh mortar. If the mortar has
set, the only way they can be repaired
is to dig out the mortar joint where
it needs repairing, and tuckpointing
fresh mortar in its place. |
| 5. |
Observe the wall and make
sure it has not been splattered or smeared
with mortar. If it has, let the spatter
or smear dry off before flicking it off
with a trowel or rubbing it off with
a piece of block/brick. |

Once
the mortar is fingerprint hard, the vertical
joints are tooled with an s-shaped jointer.
The horizontal joints are also finished
and any burrs which develop between the
points where the horizontal and vertical
joints come together, are flicked off with
the blade of the trowel.
Once
the joints are tooled, a final inspection
should be made to be sure of a tight
bond between mortar and block and that
there are no ragged edges. The wall is
now ready for cleaning and finally, a
stucco finish can be applied if desired.