The new roof is finally getting installed and Katie and I are proceeding with prep work for the new windows. This includes removing the old rotted windows which uncovered a new challenge. The brick work around the windows has suffered quite a bit of damage over the years and there is nothing in the budget for repair; as a result, I’ve now become a budding mason.
Almost every window has seen quite a bit of water infiltration over the years and this would not have been a problem if the brick work was more modern. These old bricks, however, were not fired as evenly as newer ones and they vary in hardness by quite a bit. Some are hard enough to daunt a concrete drill while others crumble with the least bit of stress. The mortar is also quite antiquated in that it is probably just lime and sand which looses its bonding ability after many years. Many of the bricks just lifted right out or their mortar bed as if they were just sitting in dry sand.
Now, it’s important to note that when restoring old brick masonry, modern mortars are too hard for the old soft bricks and can cause them to disintegrate over time. With this in mind, the mix that I use is similar to the old lime and sand but it also has a dash of Portland cement. This creates a mortar that is soft enough for the old bricks but has added durability from the Portland cement.
The repaired sills are probably good for another hundred years and maybe longer.
Another part of the window that suffered over time is the nailing blocks. These are wooden bricks embedded into the window opening so that the window jambs have something to attach too. Most of the originals were just loose and had to be pulled out leaving a pocket.
With a bit of mortar, it was easy enough to put the nailing blocks back in for securing the new windows.
As a beginning mason, all my handiwork will be covered by the window jambs and casings. Perhaps this is a good thing since I’m still working on making the work look pretty. In the meantime, I’m learning about mortar consistency, differing types of sand and protecting my hands from undue wear and tear.
On this last point, I discovered the hard way that the lime used in mortar likes to eat skin. It’s quite irritating and where the skin cracks from dryness, the mortar goes subcutaneous and leaves little gray scabs that hurt for about a week. I now wear surgical latex gloves under rubberized cotton work gloves. This provides suitable protection without rendering my hands too clumsy for handling the mortar.
With luck, the next post will have the new roof completed and walls installed on the first floor. Keep your fingers crossed.