Chimney Masonry Repair

Tools:

grout rake
brick chisel
masonry hammer
wet/dry shop vacuum
wire brush
broom
water spray bottle
bucket
trowel
wooden spoon
hawk (basically a handheld tray for mortar)
tuck-pointing tool
trowel
gloves
safety glasses
grout or masonry mix
acrylic concrete and grout fortifier

Steps:

1. Put on some safety glasses and go to work digging out the old loose mortar with the grout rake (figure B). Use a hammer and brick chisel to take care of hard spots.

2. Flip the grout rake over and enlarge the joints a little by using the flattened head on the flip side of the masonry nail. Clean up the mess with the vacuum.

3. Run a wire brush over the joints to remove more dust (figure C) and vacuum once again.

4. Moisten joints by spraying water on the chimney. Dampening the old mortar helps the new mortar adhere better.

5. Mix mortar and fortifier according to directions. A wooden spoon makes a handy tool for mixing. The mix should be thick but still workable. Give the mix time to rest and soak up all the water.

6. Load up the hawk with a fat pile of mortar (figure D), and hold it up to the chimney. Use the tuck-pointing tool to pack the joints full of mortar (figure E). Hold the hawk just below the mortar line, and use the tip of the tuck tool to pack mortar tightly into the joints until it's flush with the bricks. Try to get as little mortar as possible on the bricks, as it's work to chip it off when it dries.

7. Give the mortar about a half-hour to dry, then come back with the trowel and scrape off excess, leaving the joints flush with the bricks (figure F).

8. Spray the mortar with water again so it will not dry too quickly, which could cause it to crack. A couple of days later, go back with a good stiff broom and brush the chimney again to get rid of any residual sand and dust.