Method Statement for Dismantling Gable Brickwork

Rebuilding and Pointing

Walton Hall
Issue 1 – May 2014
 Contents

1. Recording and Preparation ................................................. 1

2. Dismantling........................................................................... 1

3. Rebuilding............................................................................. 1

4. Brickwork Repair.................................................................. 2

4.1 Preparation:............................................................................ 2
4.2 Pointing: ................................................................................. 2

4.3 Replacement of Individual Bricks: .......................................... 3

Issue date: 7 May 2014

Prepared by: Jennifer Chambers
Checked by: Caroline Drake

Bridgegate House
5 Bridge Place, Chester CH1 1SA
01244 350063

www.insall-architects.co.uk

Donald Insall Associates Method Statement for Dismantling Gable Brickwork Rebuilding and Pointing
 1. Recording and Preparation
Prior to commencement each area should be photographed in high resolution and
the photographs both sent to the architect for their records and printed off and
made available on site.
Any peculiarities (e.g. deviation to standard bond) should be noted up on the site
photographs.
Bricks definitely requiring replacement should be marked up on site by the
architect. The exact (brick by brick) extent of dismantling will be chalked on the
wall be the architect or marked on a photograph
The contractor must ensure that adequate propping is in place and nearby parts of
the building (particularly the stonework) are projected from accidental damage.

2. Dismantling
Brick dismantling should be carried out with care by an experienced mason(s) to
conserve the maximum number of sound bricks.
Each brick is to be carefully cleaned during dismantling to remove any mortar,
avoiding breaking off brick arrises during the process.
Any remnants of ferrous fixing are to be removed, including cramps etc. When
removing the modern replacement pinnacles and coping stones the emphasis
must be on minimising damage to the brickwork to be preserved.
Only bricks with at least one half undamaged should be retained. Whole,
undamaged bricks should be separated from those with some damage but
suitable for cutting. Numbers of damaged bricks should be recorded and the
information made available to the architect as soon as possible, to enable
replacements to be sourced if necessary.
The sound bricks should be stacked on timber pallets (each gable separated) or
an agreed area of the scaffold (if the structural engineer agrees it is safe to do so
and rebuilding is to occur immediately). The numbers of layers on a pallet must
be within the limit of safe mechanical handling.
Bricks must be stacked in an agreed way to ensure that lifts and the order of
disassembly can be clearly identified. Stacks should be clearly and appropriately
labelled – e.g. indelible ink on white roofing felt.
Any pallets of bricks should be wrapped and placed in a secure position, away
from risk of theft and accidental damage.

3. Rebuilding
Unless agreed otherwise, rebuilding should be carried out by the same experience
mason(s) that dismantled the brickwork and within a short a time period as
possible.
All brickwork is to be reconstructed using the original bond and bricks should be
replaced in their original position unless otherwise agreed with the architect (for
instance where re-using a brick from a hidden area to replace a damage facing
brick).
Bricks must be reinstated in their original orientation – e.g. not turned to expose a
previously hidden edge.
Damaged bricks may be used for cutting if required.
Works to the pinnacles and coping stones are to be as drawing 3300. Mortar for
the brickwork is to be hydraulic lime (without cement) in accordance with the
methodology for pointing noted below.
Upon completion the contractor should hand to the architect a final set of marked
up photographs showing extent of rebuilding and any replacement bricks. This
information will be made available to the conservation officer for their records.

Donald Insall Associates Method Statement for Dismantling Gable Brickwork Rebuilding and Pointing 1
 4. Brickwork Repair

4.1 Preparation:
In preparation for re-pointing works, rake out all loose jointing material to a depth
of not less than twice the joint width. All raking/cutting shall leave a clean, square
face at the back of the joint.
The prepared face and joint should be carefully cleaned out with a bristle brush
and thoroughly flushed out with clean water. All dust and loose material must be
removed, working from top to bottom of the wall.
No cleaning agents or fungicides are to be used either before or after repair works,
except on the express authority of the Architect.
Any sound pointing internally should be left undisturbed, even if it has weathered
back behind the general wall face to as much as half the joint width. Generally,
the existing mortar should be capable of being removed by raking out with a blunt
instrument, leaving the arrises of the brickwork or stone unharmed. A hammer
and chisel should only be used when expressly permitted by the Architect.
The use of angle grinders and other mechanised cutting tools is not permitted.
The only possible exception to this will be to form a groove in a horizontal cement
filled joint in order to cut it out with a chisel. The Architect’s approval must be
given before using this method.
Where it is desirable to remove unsightly cementitious pointing, experiments
should be carried out to the approval of the Architect to ascertain the most
appropriate method of removal and limit damage to existing fabric.

4.2 Pointing:
Samples of mortar mix and pointing should be prepared for architect’s approval
and retained on site as a control sample for the duration of the works. Hydraulic
lime mortar should match the colour and texture of the existing bed joint mortar.
Based on analysis of the original mortar, anticipated mix is 1:3 (NHL3.5: aggregate
comprising sand and grit) as follows;
1.5 nosterfield sand
1.5 Layton buzzard sand
1 hydraulic lime 3.5
It is essential to thoroughly dampen the masonry before pointing commences. In
dry conditions the wall may need to be wetted down two or three times. No water
should be left lying within the prepared joints.
The mortar should be pushed into the joint and firmly ironed in with the maximum
possible pressure and minimum over-working. Pointing irons should be used, not
trowels. The pointing irons should be of a width which will fit into the joint and
ensure full compaction is achieved throughout the depth of the joint each time
mortar is placed rather than from the surface alone. The Contractor should be
aware that it may be necessary to fabricate pointing irons to undertake the works.
Re-pointing work should begin at the uppermost section of the wall and proceed
downwards, ensuring that all the mortar is pressed well into the joints to achieve
good compaction. Fill all the joints solidly with the approved mortar mix finishing
either flush or very slightly back from the masonry, in accordance with the
approved sample.
Where mortar joints to be repointed exceed 30mm in width (and no specific
instruction for reinforcement is given), a piece of quarry tile(s) cut to a suitable size
should be inserted to pack out the joint.

Donald Insall Associates Method Statement for Dismantling Gable Brickwork Rebuilding and Pointing 2
 The mortar should be left to take its initial set and then be worked over with a stiff
bristle brush. This should counteract shrinkage and provide a suitable finish. The
bristles should not be dragged across the face but tapped against it. Timing is
critical. If this technique is applied too early the mortar will be removed too easily,
if too late, it will be difficult to make the required impression. The timing will
depend on the weather and type of lime used (hydraulic limes may achieve an
initial set within a couple of hours whereas non-hydraulic ones may take a day or
two). The aim should be to produce a joint brushed back 1-2mm from the arriss of
the bricks.
Any slight fractures due to shrinkage must be cut and re-made.
In warm weather lime mortar should be protected from drying out too quickly with
damp hessian. In cold weather lime mortar work should only be carried out when
temperature is min. 5 degrees and rising, refer specification for further detail.

4.3 Replacement of Individual Bricks:

Prior to starting the existing area must be photographed and retained as a record.
Each brick identified for replacement is to be cut out by hand. Angle grinders or
other mechanical tools must not be used unless a minimum of 4 bricks adjacent
are to be cut out, and then only to create the initial break and break out the bulk of
material at the middle of the bricks. All cutting out must not damage adjacent
brickwork in any way. Whole bricks are to be cut out, including the surrounding
mortar to the bed, perpend and back joints. The faces of adjacent bricks must be
cleaned ready to receive the new mortar and brickwork. Maintain necessary
protection from water and other potential causes throughout.
Clean out newly exposed opening. Wet surrounding brickwork thoroughly before
rebedding new brick. In dry conditions keep it damp as work proceeds to prevent
de-watering of the mortar. Ensure that the joints to the surrounding remaining
bricks are kept full to retain stability – if in doubt consult the architect and/or
structural engineer.
When bedding in the new brick, set the mortar back for later pointing. Follow
original coursing and bonding as recorded. Ensure that joints are not widened
during construction. Protect mortar as described in 4.2.
The colour, size and surface texture of the replacement bricks are to match the
existing accurately. The type of brick to be used should be agreed in advance by
the architect. Bricks are to be free from deep or extensive cracks, from damage to
edges and corners, from pebbles and from large particles of lime.

Donald Insall Associates Method Statement for Dismantling Gable Brickwork Rebuilding and Pointing 3