There is a lot of science in making bricks that meet stringent engineering standards and hold up to the weather. And there is plenty of art in masonry, keeping every line plumb and unerring.
Through minute study of the motions required for laying a brick under standard conditions, Gilbreth reduced them from eighteen to five movements per brick.
Preparation
Bricklayers, also known as masons, use brick and other blocks to construct walls. This work can range from building a garden wall to installing a complex facade on a high-rise building. A bricklayer’s job duties include laying brick walls, cutting and shaping stone and concrete blocks, pointing mortar joints, cleaning masonry structures and waterproofing.
The first step in bricklaying is preparing the site and ensuring you have the right tools for the task at hand. This may be as simple as ensuring that all bricks and mortar are within easy reach so you don’t have to constantly move around the structure, or it could involve erecting and dismantling scaffolding or lift machines.
It’s important to lay a bed of mortar on the footing as you start your brickwork, this will help ensure the bonding between the bricks is strong and will protect it from moisture changes or shifts in temperature. It’s also good practice to soak the bricks before you begin laying them so that the mortar has time to set, and this will reduce the risk of the bricks falling off during the process.
Gilbreth’s first step in advancing the science of bricklaying involved establishing a system of training his men to be first-class bricklayers. This was done by watching them work and giving them constant help, instead of the previous approach that saw managers stand back and throw responsibility onto the workers. He also introduced simple apparatus, like his adjustable bricklayer’s scaffold and packets for holding the bricks, that eliminated a lot of tedious motions.
Laying
Bricklaying is a skilled trade, but you don’t have to be an expert to get started. All you need are a few tools and a plan to start building your own brick walls. The major materials you’ll need are bricks and mortar, which consists of four parts sand to one part cement with plasticizer added for easy workability. You’ll also need a trowel, a spirit level, and a gauge rod.
First, make sure that your bricks are thoroughly soaked and then let them dry before beginning to lay. This is important because it allows the mortar to set and create a strong bond between the bricks. Once the mortar is ready, it’s time to start laying the first course of bricks.
To begin, lay a small bed of mortar at one end of the wall, three bricks along. Then, place your first brick on the mortar bed and tap it with the butt of your trowel until it is set. It’s important to keep the brick flat and aligned with the line you’re working from.
At this point, you can continue laying courses of brick until the structure is the desired height. During this process, it is important to keep in mind that a single bad brick can derail an entire wall. That’s why it’s so important to take your time and be meticulous with your work.
Finishing
The finishing of bricklaying is a process which combines art and science. The final quality of the brickwork is affected by how the mortar is prepared and how it is applied.
For instance, it is important that the mortar is raked out evenly in the joints. A metal tool known as a “chariot” can be used for this purpose. However, it is also important to make sure that the mortar isn’t pressed back too far into the joints because this can cause water to collect and damage the brickwork.
Similarly, the surface finish of the joints affects how light hits and highlights the brickwork. If a joint is too wide, it can highlight the individual bricks and the texture of the wall; however, if the joint is too narrow, the effect of light shining through the brickwork will be diminished.
Gilbreth developed these techniques in order to increase the productivity of his bricklayers and achieve a harmonious relationship between them and their work. He did this by first analyzing and studying each workman’s movements, eliminating any motion that was unnecessary or slow and substituting it with the most efficient motion. He also saw to it that all those who were preparing the bricks, adjusting the scaffold and so forth cooperated with the workmen by doing their jobs right and fast.
Maintenance
Bricklayers work with a variety of materials and can construct or repair walls, structures, chimney stacks and paths according to blueprints and specifications. They could work for construction companies or be self-employed. They might also install firebrick in commercial and industrial furnaces and incinerators. Some bricklayers are specialized in masonry repairs and restoration projects.
They might use various electric tools to cut and shape bricks or cement blocks. They might also use a variety of hand tools to shape and smooth mortar joints. They might also use caulking and other materials to waterproof building structures.
Water damage is one of the biggest threats to brick structures. Long-term soaking and the absorption of mineral salts can cause brick to deteriorate. Bricklayers can prevent this damage by ensuring that all flashings are in good condition and reducing the amount of moisture allowed to penetrate a building’s structure. They can also reduce water damage by directing surface runoff away from the building and eliminating pools of water.
The qualifications needed for a career as a bricklayer vary by country and province, but generally include on-the-job training combined with classroom studies. In the United States, bricklayers often complete a three- to four-year apprenticeship program where they earn while they learn. They usually receive a percentage of a journeyperson’s hourly wage during their apprenticeship, but once they finish their training, they can earn at the full journeyperson rate.