Masonry Repair
Bricks, stones, and concrete can be used to make beautiful home siding, chimneys, fences, and walls. With preventive maintenance and occasional masonry repairs, these structures can last for years.
Masonry Repair Charleston SC can involve fixing a brick chimney, repairing stone patios, or even restoring historic building facades. If a wall, chimney, or other structure needs restoration, it is important to have qualified masons take a look at it to see what kind of repairs are needed.
Cracks in masonry can be caused by many different things. They can be a sign of foundation problems, or they could just be due to settlement. It is important to determine the cause of the cracks in order to correct them and prevent further damage. It is also a good idea to have an engineer evaluate the cause of the cracks in order to make any necessary structural repairs.
One type of masonry crack is caused by thermal movement and shrinkage. These types of cracks often appear at the interface of dissimilar materials, such as at a joint in a brick wall. They can also occur at openings, such as doors and windows, or where a building connects to adjacent buildings or walls of different heights. It is possible to minimize these types of cracks by ensuring that the masonry materials have different exposures and conditions and by installing expansion joints in such locations.
Another common type of masonry crack is caused by moisture changes. This is often seen as horizontal or diagonal cracks in brick walls, but it can also be caused by other issues, such as inadequate venting or freeze-thaw cycles. It is important to ensure that water is directed away from the foundation and through the proper drainage systems to reduce these types of masonry cracks.
Brick cracks can also be caused by a number of other issues, such as improper grading or drainage, or by non-standard brick or mortar. It is important to note that just filling in the cracks will not fix the underlying problem, and they may reappear.
Some other common brick cracks include stepping cracks and vertical corner cracks. Stepping cracks are due to a buildup of pressure in the wall, while vertical corner cracks are often caused by drought-like conditions that cause the soil to shrink and move downhill. These types of cracks can be a sign of serious foundation problems, and it is important to consult with a masonry company. They can use a combination of methods to repair these cracks, including hydraulic cement and injection epoxy.
Cracked Mortar
Mortar cracks are a common issue with masonry walls, especially in homes. Most are minor and can be ignored, but others can signal the need for major home repairs. The underlying causes of the cracks vary, from soil movements and climate changes to structural overloading or point loads.
Most masonry structures are built from brick, concrete blocks, or stone laid on beds of mortar. The mortar joints are intentionally weaker than the masonry units, so that any movement in the structure will first show up at the joints rather than at the bricks or stones. This prevents stress from being concentrated on the weakest part of the structure and helps extend the life of the masonry materials.
Unfortunately, the mortar joints are also the most vulnerable to moisture damage. Moisture penetration through the masonry units and into cracks in the mortar will erode the mortar, which eventually leads to crumbling and deterioration of the bricks. The damage will continue to worsen unless the moisture problem is addressed.
The first step to repairing mortar cracks is to clean the old mortar joints. This can be done by scraping loose mortar off the brick face or using a hammer and chisel to break up and chip away the damaged mortar. Make sure to wear safety glasses and a dust mask while working. After cleaning, you can prepare the mortar for new repairs by lightly spraying it with water to moisten it.
If your masonry wall has expansion cracks, have an engineer evaluate the structure to determine the cause of the movement. If the structure is not designed properly, expansion cracks will likely result from overstressing structural elements. The cracks can be relieved by the installation of control joints, which are saw-cut into the wall at a predetermined spacing.
Most masonry wall cracks are due to movement in the underlying soil. As the soil settles, the bricks and their mortar will shift slightly. This can cause small vertical cracks or, in more serious cases, severe structural instability.
Cracked Brick
Mortar cracks are usually minor and can be repaired with a process known as “repointing.” This is the process of filling in the open spaces between bricks or stones that are held together by mortar. Cracks that impact only the bricks or stones themselves will likely need to be addressed through a more extensive approach. This can include managing water or other issues that may be affecting the entire structure.
Cracks that occur within the mortar joints can often be caused by thermal expansion and contraction. This type of crack is not unusual in Michigan, where climate changes can affect masonry structures and the soil they sit on. If these cracks do not exceed 1/2 inch, they are considered normal and need not be addressed further. However, cracks that are larger or extend further into the bricks themselves should be addressed.
Masonry cracks are also often caused by movement of the underlying footing or slab that the structure rests on. This is particularly common in older homes where the original footings were built into and on top of the soil. This type of crack is most often seen in load-bearing walls where the internal tensile stress on the wall is greater than the structural integrity of the footing.
Load-bearing walls should be inspected after any major weather events or seismic activity. A professional mason will examine the cracks and determine if they are caused by a foundation issue and, if so, how serious the problem is. They will then recommend the best course of action to repair the damage.
When repairing cracks in masonry, it is important to use the right repair material. Many people make the mistake of using concrete repair epoxies to seal brick cracks, but this is often ineffective. Epoxy does not bond well with brick, and it may change how moisture vapor passes through the wall, hastening the deterioration of the structure. Alternatively, it is recommended to use a mortar mix that matches the color and texture of the existing brick. This will create a more seamless appearance and help conceal the cracks in the brick.
Damaged Stone
An annual inspection of stone walls by a masonry professional can prevent small problems from turning into large, costly structural failures. These can be caused by erosion, frost heave, and damage to the stone itself. A collapsed stone wall presents a major safety hazard and needs to be repaired as soon as possible.
The simplest and least expensive way to repair stonework is to repoint the mortar joints. This process is also referred to as “tuckpointing.” It involves cleaning the mortar joints, removing any loose or crumbling material, and repointing the joints with new mortar. In stone masonry, the joints are the weakest link and can be easily eroded by water and freeze-thaw cycles.
A masonry mason can use a hand trowel to thoroughly clean the cracks and then fill them with vinyl concrete patcher that has been stained to match the color of the stone masonry. It is a good idea to spread the patcher evenly over the entire crack and then use a pointed trowel to smooth it out and remove any excess material. The patcher will dry for 24 hours, and then the surface of the masonry can be sanded with medium-grit sandpaper to finish it off.
Some stone surfaces are prone to delamination and erosion, especially if they contain lots of veins or if the stones were quarried from soft rock deposits. The occurrence of this type of damage can also be exacerbated by incorrect bedding. For example, copings and cills are usually edge bedded; however, in this case they were face bedded, possibly because it was difficult to discern the bedding pattern or because of ignorance of the consequences.
Other natural causes of deterioration include mechanical damage by the roots of ivy, which may split stone if it enters through crevices. Biological damage may be the result of bacteria that attack the stone or the oxidation of sulfurous acid in polluted air that eats into the surface of the stone.
How to Properly Repair Concrete
A homeowner who sees a crack in concrete might assume that it requires extensive repair, but the type of damage is often more important than the size. It’s also crucial to understand how concrete is different from wood or metal and the proper methods for repairing it.
The best repair materials have low shrinkage because the host concrete has already gone through its own cycle. High shrinkage can cause debonding and failure. Contact Concrete Repair Colorado Springs for professional help.
The success of any concrete repair job depends on proper surface preparation. It is also dependent on using the right repair material. Contractors can use a variety of cement repair products, but it is important to select the product that will best match the type of concrete that needs repaired. The right repair material should be durable enough to serve its intended purpose and should have a service life longer than the existing concrete.
The most common reason that concrete repairs fail is due to a lack of a good bond between the new and old concrete. The quality of the bond is a direct result of the care taken to prepare the surface of the old concrete before the new repair work is put on.
When a contractor is replacing damaged concrete or performing an asphalt patching job, the same good practices should be followed as for placing new concrete. This includes cleaning the surface, scrubbing it, and flushing it with water to remove any loose material. This will ensure that a strong bond is formed between the new concrete and the existing concrete. A bond coat, such as a vinyl-patching compound, should be used to get a good seal.
Contractors should undercut the repair area by five degrees when they are cutting sidewalk flags to prevent a gap between the new concrete and the existing pavement. This undercut will mechanically lock the new concrete to the existing concrete and will also reduce early-age shrinkage.
Portland cement mortar and grout are the most common repair materials used for concrete surfaces. These should be mixed with water to form a thick paste, which should be troweled into the cracks and broken concrete areas. The mortar should be tapped properly to remove air gaps. A final textured finish should be applied to the repaired surface.
In some situations, a urethane sealant can be used to fill in the cracks. This does not create a structural bond and will not stop water from flowing through the cracks, but it does provide a waterproof seal. When a contractor is looking for a concrete repair method that will provide both a structural bond and stop water flow, epoxy injection should be considered.
Mixing
The mixing phase is where contractors get creative. In addition to following package directions for mixing, they must also consider the geometry and structural needs of the repair. For instance, a contractor should not use the same mix for a sidewalk as they would for a driveway because their strength requirements will be different. Concrete mix manufacturers have created a variety of mixes to accommodate the many situations that may arise on a project. It is important for contractors to choose the right one.
The area in need of repair should be swept clean to remove debris, dust, and other contaminants. Then the area should be rinsed with water to make sure it is free of any remaining chemicals that could impact the bond between new and existing concrete. A contractor should also hose off the surface to prepare it for the concrete repair. This helps to ensure the new concrete will adhere and prevent future cracking.
A contractor should also ensure the weather is conducive to pouring concrete. Contractors should check the forecast and know the minimum temperatures, maximum temperatures, and humidity levels needed to pour the concrete for a successful repair. They should also have the necessary tools to complete the repair on site, such as a wheelbarrow or truck to transport and dump the concrete, a cement mixer, and a drill with a paddle attachment for mixing the concrete.
Once the preparation and mixing are complete, the contractor should spread the concrete on the repair site. It is a good idea to use a feathering technique to blend the new concrete into the surrounding dry concrete. This adds to the professional look of the finished product. A texturing tool is also recommended if desired, depending on the setting of the repaired concrete.
All repairs should be properly textured to match the existing surface. Contractors should also ensure the texture is consistent with the cross-section of the repair. If the repair abuts a working joint or crack, a compressible insert medium should be used to maintain the integrity of the repair.
Applying
Concrete repair is a complex process, but there are simple steps to take that will ensure the results are good. The most important aspect is making sure the surface of the old concrete that is receiving the new repair is clean. This can be done by sandblasting, shotblasting, or a similar process. This step is important because if the old concrete is not clean, it will not bond well with the new concrete.
The next step is to apply the new concrete or patching mix to the existing concrete. This can be done using a trowel, but some people also like to use a hand float to create a smooth surface. For larger repairs, a hand or power broom may be used to finish the concrete. For vertical concrete sections that will be replaced with new concrete, a form must be constructed to hold the concrete as it sets.
When repairing cracked concrete, it is necessary to understand why the cracks are occurring. Once this is understood, the proper repair method can be selected. There are several different methods of concrete repair, including epoxy injection, routing and sealing, stitching, drilling and plugging, and gravity filling.
If the deterioration of the concrete is serious, it is recommended that a registered professional engineer be hired to determine the severity of the damage. The engineer can then make recommendations for the appropriate repair method.
During the application phase of concrete repair, it is important to use a quality product that is designed for this type of work. This will help prevent the common problems that can occur, such as premature deterioration or failure of the repair.
For example, a structural repair may require the addition of reinforcing steel to increase the tensile strength of the concrete. This is not an easy task and should only be done by a registered professional engineer.
It is also important to mix the concrete properly, as this will affect whether the repair will last or not. For this reason, many bagged concrete mixes are designed with safety in mind. For instance, they are made with silica removed to comply with all current safety regulations. Additionally, manufacturers such as Quikrete have started to incorporate fibers and polymers into their products to help resist cracking.
Finishing
All concrete has a limited “shelf life.” If it’s exposed to the elements for too long, it’ll degrade and crack. This isn’t a bad thing, but it can be a problem when you need to repair concrete structures. The process of repairing concrete involves reinforcing the concrete to hold it together again.
Choosing the correct concrete repair material is a crucial step in this phase. The right product will help prevent damage to the structural steel, improve the bond with the existing concrete, and provide a strong surface that can stand up to traffic and the elements.
The most common repair materials used are Portland cement mortar or grout and cement concrete. Portland cement grout is ideal for small repairs because it is easy to mix and apply. This product is also able to resist chloride attack, which can be caused by corroded metal embedded in steel reinforcement. Portland cement concrete, on the other hand, has a higher strength than cement grout and is recommended for large-scale concrete repair projects.
It’s important to note that major concrete repair projects should be handled by qualified professional engineers. These professionals can help you determine the cause of the deterioration and design a suitable repair method. They can also assist you with the selection of the appropriate repair materials and construction techniques for the structure in question.
In addition to ensuring that you have the right type of concrete repair material, it’s also vital to make sure that your surface prep is done correctly. The concrete should be clean, free of oil and dirt, and have a proper consistency. Depending on the type of repair, you may also want to add a texturing element to the concrete. This can help enhance the aesthetic of the repaired area and add some visual interest to it.
Finally, the concrete repair must be properly cured. This is accomplished by keeping it moist and preventing it from drying too quickly. This can be achieved by covering it with plastic or using sprinklers around the work site. The length of time for which this is necessary will depend on the mix and the weather conditions.
