We have had several jobs where we needed to repair or rebuild stone or concrete. This is the first job we were asked to rebuild brick.
Our home brewed recipe of urethane cement is what we decided to use. What makes this recipe so good for repair is what also makes it a challenge. It sets up very quickly. We have to mix small batches. The other thing I don’t like about it is that it is very hard on your hands. Any type of glove that is practical to use deteriorates very quickly. Cleaning your hands as much as possible and when done applying a good amount of lotion helps.
I tried to form each brick as the layers were built up. The entire process was done over four days. On the third day I used a grinder with a wire wheel to clean up the brick. I also decided to use a diamond wheel to cut and define the mortar lines a little bit more. The fourth day was mostly finishing touches.
After the brick work was done we used a high alkali primer on the repaired areas and then painted as usual.
The brick rebuild was much more difficult then other repairs we have done but the end results were good. The customer loved it.