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Brick Patio Mortar Repair

By Tim Carter
©1993-2008 Tim Carter
Summary: Brick patio designs are as abundant as grains of sand on a beach. A brick patio with traditional mortar joints has a timeless look and feel. Building a brick patio using brick pavers can be a chore. You must use Portland cement mortar and fine sand so the brick sticks forever to the concrete base.

DEAR TIM: I have a lovely brick patio that has mortar between the brick. After pressure washing it this past weekend, I noticed several locations where the mortar has disintegrated. Most of the mortar is in excellent condition, but a few places need to be repaired. Some of the voids are 1 inch deep, while others only need perhaps one-eighth inch of mortar. How do I mix the new mortar, and what tools do I use so I don't make a mess of things? I have lots of free time, so what are the best weather conditions to work in so the repairs last a long time? Holleay P., Kitty Hawk, NC

DEAR HOLLEAY: Brick patio designs are as plentiful as blossoms in spring, but a traditional brick patio that has been mortared in place is one of my personal favorites. These patios are like a brick wall that is lying flat on the ground, and the mortar becomes an interesting design element because of its texture and color. I have two brick patios just like yours, and they get compliments each time a friend or neighbor sees them for the first time.

These deep joints can be filled with new mortar using the special grout-bag tool. Once the mortar is stiff, scrape off excess with the small trowel. PHOTO CREDIT: Tim Carter
When I am building a brick patio like the one you and I have, I use a special mortar that will withstand years of Mother Nature's abuse. It sounds like your builder did the same thing, but the mortar in a few locations was defective. That has happened to me in a few spots on my own patio. I traced the defects to excessive water from a rainstorm that happened soon after one section of the new brick was grouted.

I suggest you repair the defective joints in your patio with the same type of mortar mix I used when I installed my patio. It is extremely durable, and will last for 40 - 50 years, if you cure the joints once they are installed. Your biggest challenge is going to be matching the color and texture of the existing mortar. You did the right thing by thoroughly cleaning the brick and mortar first. All too often, people try to match mortar colors and fail to clean the surrounding mortar first. Mortar on walls, and especially on flat patios, can get very dirty.

The first thing you need to do is look very closely at your existing mortar joints. Look at the color of the sand. Believe it or not, not all sand looks the same. Sand is simply a collection of very small rock particles, and the color of individual sand particles can be vastly different if the particles come from a variety of black, red, white and gray rocks. Visit different building supply businesses and/or sand and gravel pits, and try to find sand that matches both in color and particle size.

Once you have the correct sand, mix it one part of it to one part of pure Portland cement. This will make a very rich mixture that will be exceedingly strong. You need this strength, even though you do not get too many extremely cold days. The extra cement also helps make the mortar flow easily from the tip of the special grout bag you will use to fill the defective mortar joints. Mortar grout bags are just like icing bags used by professional cake decorators. They are larger than an icing bag, and have a metal cone tip that has a one-half-inch hole at the end.

I prefer to work on cloudy days when the temperature is in the 50 - 65 F range. Do not work on a hot, sunny windy day. The mortar will dry too rapidly, especially where you are filling slight depressions in the existing mortar joints.

Once you have the mortar mixed, lightly spritz the mortar joints you are going to fill. Do not get them too wet, just slightly damp. Fill the grout bag half way with the mortar mix, and apply slight pressure to make the mortar mix flow just as toothpaste oozes from its tube. If you can't get the mortar to flow, you need to add more cement and/or slightly more water. The mortar mix needs to be fairly wet so that it doesn't clog the grout bag tip.

Check out the different colored pieces of sand. Each grain is a small piece of solid rock. The sand for the repair job should match the existing sand as close as possible in grain size, shape and color. PHOTO CREDIT: Tim Carter
Carefully guide the grout bag tip so that you apply new mortar only to the joint. Move the bag along and make sure you apply mortar so it rises above the level of the brick by about one-quarter inch. The fresh mortar needs to touch the top edges of all the brick. Let it set until you see it change from wet and glossy to a flat gray color. Use a small triangular trowel to gently scrape off the excess mortar so the top of the mortar is flush with the brick. Keep the fresh mortar damp for three days so it cures well.

If you scrape the excess mortar too soon, it will smear onto the brick. You do not want this to happen, especially if the brick has a rough texture or grooves created by the wire-cutting process as the brick is manufactured. If mortar gets in these grooves, it is a nightmare to remove.

You also have to be careful about waiting too long to scrape off the excess mortar. If the mortar gets too hard, you run the risk of breaking the bond between the new and old mortar. If this happens, your new mortar may fail in a few years.

 

 






Comments

BC Wilson
15 Feb 2008, 14:33
Tim, I have put a stone veneer fireplace in my greatroom using marble thinset and now need to do the mortar joints. I am planning to use a mortar bag but I have some questions:
1. If I mix my sand and cement the same every time (1 to 1) will the color stay the same?
2. I have a large variety of mortar joints (1/2 inch to 1 1/2 inch), so I quess it depends what look I want but do I need to point it up after squeezing in mortar? or can I just brush the joints?
Any other info would be appreciated.
I used the oxygenaged cleaner and non-linseed based sealer you suggested with good success.
Thanks, BC
AsktheBuilder
15 Feb 2008, 18:25
BC,
The color should be the same. Use the same amount of water! Can't help on the joints, you will need to experiment.
Peter LaGrassa
01 Apr 2008, 13:57
I have been trying to use a grout bag to fill mortar joints on stoops and on brick projects so I don't make a mess. The problem I am having is trying to get the mortar to come out of the tip. If it doesn't come out, I add more water. If the mixture is too dry, the tip clogs up. I really wld like to use the bag, but can't seem to get it to work. Can you give me any advise about this. Thanks.
AsktheBuilder
04 Apr 2008, 06:20
Peter,
I tell you in the column above exactly how to solve this problem. Read the last third of my answer again. The mortar needs to be fairly wet to flow, but you need to do one other thing..... My mortar joints probably have a compressive strength in excess of 6,000 PSI.
Jan Pittman
07 May 2008, 15:56
Can I store mortar mix in my basement, off the floor, where the summer humidity is about 70% for 4 months?
AsktheBuilder
19 May 2008, 08:00
Jan,
It is a bad idea to store the mortar in conditions like that. You want an area where the humidity is very low.
Bart Barrett
27 May 2008, 17:14
I put in a large patio this weekend using big paver stones. After sweeping the dry morter in the joints, then wetting with a hose, I cant get the dried residue off the stones. Will weather bring back the orginal color, or am I going to be stuck?
AsktheBuilder
12 Jun 2008, 11:47
Bart,
Mother Nature will remove it, but it will take time. You can also do it with muriatic acid and water.
greg
13 Jun 2008, 14:13
A mess with brick pavers? A guy i know told me he has done many paver jobs with mortar. I went by an old house he said he done, nice. When he started mine, I got a clue he had no idea. He smeared mortar all over the face of the bricks, How can I clean this mess up? Is sandblasting a good idea?
I am doing the job now, learning curve for sure.
jack b.
17 Jul 2008, 02:03
Tim, i have a problem... I build a brick barbeque grill with a granite countertop. the cement has left a stain on the brick. Is there anyway i can clean the bricks without damaging my countertop?

i was also told NOT to use acid.

please help
thanks jack

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