A Step-by-Step Guide to Laying Bricks with Refractory Mortar
This guide outlines the process of using refractory mortar, a mixture of Portland cement, silica sand, perlite, and fireclay, for brickwork in high-heat settings. It emphasizes the need for complete drying before exposure to high temperatures and provides detailed steps for application.
By Sam Mitchell10 steps
Refractory mortar is often found in fireplace brickwork.
In high-temperature applications like fireplaces, refractory cement is commonly employed for bricklaying. The mortar mixture includes Portland cement, silica sand, perlite, and fireclay. While the bricklaying method with refractory mortar is similar to that using regular Portland cement, it's crucial to let the refractory cement dry fully before subjecting it to high heat. Once completely dried, this mixture can endure years of exposure to intense heat.
Step 1
Prepare the bricklaying area by sweeping and washing it thoroughly with water. Let the surface dry completely.
Step 2
Open the bucket of refractory mortar and stir the contents vigorously with a wooden stick or trowel. Since the mixture may settle or separate during storage and transport, thorough stirring is essential to restore it to a workable consistency.
Step 3
Using a margin trowel, spread a layer of mortar onto a dry brick. Generally, when laying bricks, apply the mortar to the brick itself, not the work surface. Alternatively, you can dip the brick's working edge into the mixture, ensuring the entire edge is coated.
Step 4
Place the brick immediately onto the work surface. Press down firmly to ensure a strong bond. Mortar should squeeze out from the joint as the brick is pressed into place. The joints between bricks should be about 1 mm wide and should never exceed 3 mm.
Step 5
Remove any excess mortar from the edges with your trowel and return it to the bucket.
Step 6
Take the next brick and apply mortar to its bottom edge and the side edge that will contact the first brick, just as before. Push it into position until it bonds well. Continue this process for the entire first row.
Step 7
Use a level to check that the first row is even. If adjustments are needed, gently tap the bricks with a brick hammer or rubber mallet.
Step 8
As you work, use a slightly dampened professional cellulose tiler sponge to clean the brick area. This keeps the workspace clean, removes excess mortar from joints, and wipes away any stray mortar on the surface. Rinse the sponge frequently in a bucket of water and wring it out.
Step 9
Keep laying additional rows of brick until you achieve the desired size and shape.
Step 10
If you plan to apply ceramic wool to the brickwork, place quarter-sized dollops of refractory mortar along the edge of your work surface. Starting at one end, press the wool into place with medium pressure over the mortar spots.
