DIY Network

Brick Wall: Grouting From "Rock Solid" episode DROC-109

The guys grout this brick wall...and, see the fantastic final product!

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	The guys are in the Centennial State...
	working on a wall...
	that takes the room from boring, to brick!

Materials:

Measuring tape
Pencil
Utility knife
Screw gun
1-1/2 in. drywall screws
Shop vacuum or broom and dust pan
Drop cloths including plastic sheeting
Masking tape
Cement fiberboard
4 in. grinder
Safety glasses
Construction adhesive (designed specifically for brick or brick veneer)
Caulking gun
Tile spacers (for desired thickness of brick joint)
Protective gloves
Masonry baker’s bag
Trowel
Half-round jointer (one for each person jointing)
Bullet level
2 ft. level
Premix mortar (any other material)
Mixing buckets

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E

Grouting

1. Once you have finished laying your brick, remove your drop cloth and clean up your working area. Tape a plastic drop cloth to the floor – grouting can be a very messy process and your work area should be well protected (figure A).

2. Mix your grout. Mix a premix bag of mortar according to the manufacturer’s instructions. Dean and Derek added a few shovels of grey cement for added color. Add water and mix with your trowel until the consistency is close to that of peanut butter (figure B). Mortar can be harsh on your hands – wearing gloves will protect them.

3. If you have chosen to set your sills with stone veneer, they can be set with the mortar mix. Set the mortar in the sill with your trowel, keeping it away from the brick and wood – mortar is difficult to clean up so it pays to be careful. Set your sills and check them for level side to side and front to back (figure C).

4. Grout your brick wall using the same mortar mixture. Fill a baker’s bag with the mortar mix using your trowel (figure D). Before you fill the bag, fold over the open tip to prevent the mixture from oozing out when you fill the bag. Next, test the flow of the material to make sure that the material is coming out at a controllable consistency.

5. Begin grouting the material by running your baker’s bag along your joints and slowly squeezing the mortar from the baker’s bag into the brick joints (figure E). Don’t spread too much or work too quickly – grout can be difficult to clean from the brick face.

6. Allow the grout to set up before using a half inch jointer to recess the joints. When jointing the corners, joint from the corner back to keep the grout in place and create a smooth line (figure F).

7. Once you have grouted and jointed the entire wall (figure G), brush off excess mortar with a cheap paintbrush (figure H). The grout should dry in about 24 hours.

Figure F

Figure G

Figure H

RESOURCES :

Product: Peppermill (color)
Brand Name: Old Brick Originals Thin Brick
Robinson Brick Company
1845 W. Dartmouth Ave.
Denver, CO 80110
1-800-477-9002
Website: www.robinsonbrick.com