Masonry Magazine January 1984 Page. 36
PAVERS continued
When the units are laid in place, the story pole is placed along one edge to control alignment of the rows. The straight edge is placed across the area perpendicular to the story pole to control units within a row.
The layout with legs method involves actually setting one paver, in alternating rows, along the edge of the area. A story pole will act as a guide for the spacing of the units.
Calipers are used for the layout, similar to the method described earlier. However, this time the marks are made showing the length instead of the width of the pavers.
You may use a story pole on both sides of the area, legs on both sides, or a combination of the two.
To set the first row of pavers, lay units between the legs or story poles along the edges of the area and set the units to the marks on the straight edge. With the first row established, the straight edge is set four rows from the starter row. It is carefully lined up with the leg or story pole and pavers in the row next to it are set, again to the marks. After the row next to the straight edge has been set, the row next to the mason is placed. Next, the pavers between the two rows just set are placed. It is important that the mason work from kneeling boards so as not to disturb units set.
When all four rows have been laid, check the spacing of the joints and the alignment of the units by placing a straight edge against the units. If necessary, move the pavers into alignment. Then, "beat in" the units using the beating block described earlier. This is an important step, since it not only levels the units, but also forms a tight bond between them and the setting bed.
After the four rows have been set, the joint spacing checked and the pavers "beat in," the straight edge is picked up and moved another four rows. The setting process is then repeated, again starting with the row next to the straight edge and following the sequence just described.
Whether using the rack or straight edge methods, the pavers are set until the area has been covered. Occasionally lay a straight edge diagonally across the pavers to be certain that they are on an even plane.
Grouting the open joints between the pavers is generally not done the same day. Generally, grouting will be done after all the pavers in an area have been set. Before the finish grouting takes place, sweep a damp mixture of cement and sand, the same as the deck mud used, into the joints to within about a half an inch of the top of the pavers. This should be done the same day the pavers are set, since it will key them in and keep them from moving when the final grouting is done later. Again, since the pavers were just set, it is important to work off kneeling boards.
Finally, spray the area off with a hose. This serves two purposes; first, it settles the mixture swept into the joints, and second, it washes off any mortar stains which may be on the surface of the pavers.
Grouting
The grout may be either a manufacturer's prepared mix or it may be hand mixed at the site. While specific conditions within an area may dictate a particular mix, a grout mix of one part portland cement and one part sand is commonly used.
The sand and cement should be mixed thoroughly dry. Water is added and they are mixed thoroughly to the approximate consistency required when used. Let the mix set for about 15 minutes to let it pre-hydrate or jell. Then remix and add a small amount of water if needed to bring it to the proper working consistency. The grout must be plastic enough to be squeezed into the joints, however, not too wet. Generally, grout which is mixed too wet will not be as strong as when less water has been used.
The amount of area that can be grouted at one time will depend partly upon the weather conditions, the absorption rate of the pavers and the type and consistency of the grout being used. Before the grout is placed, sealant or grout release may be applied to the paved surface to prevent grout from bonding to the units and make cleaning easier. A petroleum-based agent or floor wax is acceptable. They may be sprayed on or rolled on with a paint roller. Use the release sparingly so that it does not flow into the joints, preventing proper bond.
The pavers can be grouted using one of two methods. The grout may be poured onto the surface and trowelled