METROBRICK®

Royal Thin Brick®

Thin Brick
Installation Guide
For Field-Applied Exterior Installations

Thank you for your interest in Royal Thin Brick® or METROBRICK®

thin brick from Ironrock. This Installation Guide serves as a guide only.

ironrock.com | 1.888.325.3945 | [email protected]

About this Guide
What is Thin Brick?
Table of Contents Thin brick is a slim brick veneer which can be as thin as 1/2”. Some
thin brick is cut from the faces of full bricks while others are man-
Page 2 ...................... Material List ufactured to size without cutting. Many classic style bricks are
now offered in thin brick format as well as thin brick with a glazed
Page 3-4 ................. Surface Preparation and/or decorated finish. When you consider the different facial
textures, colors, shapes, and patterns available you ultimately real-
Page 5 - 6 ............... Setting Thin Brick ize there are many options available for thin brick. This increase in
options and popularity has led to a growing market for thin brick
Page 7 - 8 ............... Grouting installations, both exterior and interior.

Page 9 - 10 ............. Tooling the Joints Thin brick has the same look and appeal as full size brick but the
installation method is much different. The benefits of thin brick
are their versatility and structural weight reduction. They can be
Page 10 ...................... Cleaning
installed on most any wall by a qualified contractor. A different
skill set is required for thin brick than for full brick, it is more simi-
lar to tile and stone installation.

In this Guide...
This is a guide for exterior installation of field applied thin brick
with a focus on grouting methods. We will discuss the methods
of installing grout mortar into the joints and the different tool-
ing methods, sometimes referred to as joint conditioning. While
this guide provides the basics, ultimately it will be advantageous
for the installer to obtain approval of the final desired look from
the end user by performing a small (4’x4’ recommended) mock-
up prior before proceeding with the thin brick installation. The
mockup can be done with a variety of grout application methods
1 to determine which one is preferred.
Materials Needed

What materials are needed to complete the job?

EXTERIOR INSTALLATION
✓ Weather Barrier Sheet | To protect the wall from moisture.
✓ Staple Gun | To install weather barrier.
✓ Metal or Fiber Mesh Lath | To create a masonry wall for the brick to hold on to.
✓ Corrosion-resistant screws | To secure lath.
✓ Heavyweight Trimming Shears | To cut lath.
✓ Mortar | For lath scratch coat and to adhere brick.
✓ Liquid Waterproofing Membrane | To keep water from penetrating into substrate.
✓ Notched Trowel | To apply mortar to the prepared surface.
✓ Grout | To fill joints.
✓ Grout Bag | To fill joints.
✓ Joint Tool | To strike joints.
✓ Stiff Brush (NOT a wire brush) | To wipe away excess mortar.

2
Surface Preparation
Prior to installation
First, start with a substrate that would typically be in place on an
insulated building prior to installing the facade. A properly pre-
pared substrate should have steel or wooden studs, a rigid foam
board insulation, exterior rated sheathing, and 4 mil polyethylene
sheeting already in place. Any walls with out of square or bowed
sections must be flattened prior to installing weather resistant
barriers.

Steel Studs Rigid Foam Insulation

Building Felt
Exterior Rated Sheathing (2 layers for wood substrate)

(pictured - typical wall section W24IE (RFI) with metal studs)

3
Step 1
Install Metal Lath
Galvanized metal lath with a diamond pattern is attached with fas-
teners that go all the way through to the studs. Attaching the lath
only to the sheathing or foam insulation is not sufficient to keep the
façade in place. Properly installed metal lath will feel rough going
down and smooth going up.

Step 2
Apply Scratch Coat
A scratch coat of mortar is mixed and applied over the lath a mini-
mum of 1/2” thick. It should completely embed the lath and make
the wall flat and smooth, ready for waterproofing. Let the scratch
coat cure for the amount of time recommended by the mortar man-
ufacturer.

Step 3
Apply Liquid Waterproofing Membrane
To keep water from penetrating into the substrate, a liquid water-
proofing product should be applied per the technical data sheet of
the product you have selected, usually two coats with time to dry
between.
4
Setting Thin Brick
Before you begin

Grout Joint Size

One difference between thin brick and tile is the amount of size varia-
tion and, subsequently, the width of the grout joint. Joints should not
be any smaller than ¼” and often approach ½” to provide an aesthetic
similar to a full brick installation. If any tooling will be done to the grout
joint (see below “Installing Grout Mortar”), the tool must be sized prop-
erly for the grout joint. Because most grout is applied with a grout bag
or powered grout/mortar ‘gun’, the size of the grout joint must coincide
with the tip size of the applicator. Often spacers, dowel rods, or spacing
rope are used to maintain the grout joint during installation but these
should be removed prior to grouting. As with any installation of ceram-
ic products, proper accommodation of movement is required. Refer to
the industry standards and building codes for details.

Type of Mortar
Often in the brick world, the word ‘mortar’ is used for the material be-
tween the bricks. For thin brick installations, we will be using ‘mortar’ as
the material holding the brick to the substrate and ‘grout’ as the mate-
rial between the bricks. Because the number of substrates and environ-
mental conditions encountered on job sites is endless, it is best to con-
sult with the setting materials manufacturer for your specific situation.
In general, the same ANSI A118.1, A118.4, and A118.15 mortars that work for
setting tiles will also work for setting thin bricks in similar environments.

5
Step 1
Embed Thin Bricks
Once the waterproofing membrane is fully cured, it is time to be-
gin installing the thin brick. Using a notched trowel apply mortar
to the prepared surface. Embed each brick thoroughly and check
the coverage of the mortar frequently by lifting a brick that has
been installed. The back of the brick should be completely covered
with mortar.

Step 2
Apply Corners as Needed
Corner pieces are available to make the installation look like a
traditional brick wall. These bricks should be back buttered with
mortar to ensure full contact with as close to 100% full coverage as
possible.

Step 3
Readjust any Bricks/Clean any Excess Mortar
Check for any twisted bricks or uneven grout joints and readjust
as long as you are still within the working time of the mortar cho-
sen. Once the bricks have been embedded, clean any mortar out
of grout joints and off the surface of the bricks before it has had a
chance to harden.
6
Grouting Thin Brick

Before you begin

Types of Grout
There are a variety of options for grouting thin brick, each has posi-
tives and negatives. Your installation products manufacturer can help
guide you to the correct product for your situation.

Traditional Mortars
Typically when dealing with full brick installations, Type N (‘Normal’ mortar with
low compressive strength) or Type S (‘Special’ mortar with compressive strength
above 1800 PSI) mortars are used between the bricks in place of a traditional
grout. For thin bricks, Type N mortar should not be used because it does not pro-
vide any flexibility and the grout joints are not deep enough to create a suitable
bond. Type S is often used because it lends itself to ‘bagging’ although it can also
crack, spall, and effloresce over time when subjected to freeze/thaw conditions
and moisture. Many companies offer ‘Pointing Mortar’ blends specifically for thin
veneer application systems which may or may not have an ‘S’ designation.

Cement Grouts
Typical standard cement grouts used for tiling (ANSI 118.6 designation) are also
frequently used with thin brick. These grouts are relatively inexpensive and lend
themselves to ‘bagging.’ However, standard cement grouts aren’t always the
best solution for exterior or wet applications where thin brick is often used due to
increased likelihood of efflorescence and spalling from freeze/thaw. A polymer
additive may help in these situations.

High Performance Grouts

An ANSI A118.7 High Performance Grout is typically recommended by setting
materials manufacturers to minimize efflorescence and block water penetration
into and through the grout. ANSI A118.7 grouts are not always easy to ‘bag’. Some
ready-to-use or epoxy grouts also may be considered depending on the service
environment. While these grouts perform well, not all of them are easy to install
with a grout bag.
7
Step 1
The facial make-up of the brick will determine the
Choose your Grout Application Method method in which you will want to apply the grout in
the brick joints.
Grout Bag Method or Tuck Point Method
For traditional, textured non-waxed thin brick
which typically simulates full brick, the installer
will most likely need to utilize either a grout
bag (most typical) to install the grout or use
the brick mason’s ‘tuck point’ (most frequently
used for repairs) tool/method. The purpose for
these installation methods is to avoid getting
grout over the facial portion of the brick. Due
to the rough texture and porosity of the tradi-
tional brick finish if grout gets on the brick the
installer will most likely be unable to get it out. Grout Bag Method Tuck Point Method

Thin brick that has a smooth or glazed facial

Please Note:
texture can be installed by the tile setter
Sacrificial (wax based) grout release products can also be used with thin bricks
method with a traditional grout float. Bricks that will be traditionally grouted. The wax covers the small voids and is removed
with a wax coating can also be grouted with during the washing step. Penetrating grout releases are typically not sufficient
a traditional grout float. The wax is then re- for this purpose. An approved mockup showing the final look achieved with the
moved with a hot water, high-pressure spray. method being considered will help to eliminate issues once installation begins

Step 2
Apply Grout Between Bricks

Use your desired grout application method

to apply grout between the bricks. The im-
age to the right represents an application
using the grout bag method.

8
 Tooling the Joint
Other Options* Before you begin

Weathered The top edge of

Types of “Tooling” Tools
the joint is recessed while the Once you have applied the grout into the joints you will need to ‘tool’
bottom edge is finished flat with
the brick edge shedding water the joint in one of the following manners. As the name implies, you
from the joint. will need a tool to create most of these looks.

Common Tools
Concave Mortar Joint
By far, the most common joint used with thin bricks is the
concave joint. This joint is made with the help of a curved
Struck Mortar Joint The bottom steel jointing tool. This is a popular mortar joint type prac-
edge is recessed while the top ticed due to its high resistance to rainwater penetration
edge will be finished flat with and tight sealing property. It is also the effect achieved by a
the brick edge. The slope provid- traditional grout float.
ed here will pull water and hold
it in the brick, so it is best suited Raked Mortar Joint
for interior walls only.
Next in popularity is the raked joint. The joint is raked out
leaving less space between the mortar joint and the face
of the brick. Due to the ledge that is formed in the joint in
a raked joint finish this is best suited for interior walls only.
Otherwise snow, ice or water will be held in the ledge of the
joint penetrating into the wall. Care should be taken not to
remove too much grout, no more than 1/2 of the thickness
V-Joint This type of joint is of the brick should be removed when raking.
made with the help of a curved
steel tool with a ‘v’ shaped end.
Proper tooling of the v-joint Flush Mortar Joint
helps to prevent water accumu-
lation in the joint. This type of finished joint is just as it is named, the joint is
finished flush with the face of the brick. This type of finish
is typically desired if the end user intends on painting the
entire, finished thin brick assembly. In this type of applica-
tion, the installer can utilize the typical tile setter method of
installing grout with a grout float.

9 *Typically these require extra labor and may incur additional installation cost.
 Step 1
Choose Your Tool and “Tool” the Joints

Once the grout has cured to the point where it is dry to the touch,
it can be tooled into the final shape. Most thin brick installations
use a concave grout joint but others such as flush and raked are
also popular.
Concave Mortar Joint

Step 2
Clean Grout from the Face of the Bricks

Once the grouting is complete but before the grout is completely

cured, clean the grout from the face of the bricks. Cured grout
is very difficult to remove. Use a stiff brush to brush away excess
clumps. You may also need to use a wet sponge to wipe away any
remaining mortar on the brick face. If the brick was waxed, use a
high pressure, high temperature water spray to remove wax and
grout residue.
Please Note: Most ceramic thin brick can
have excess cementitious mortar and grout
removed with an acid-based grout removal
product. Check with the thin brick suppli-
er before acid cleaning glazed or decorated
bricks. Do not use acid for cement-based
bricks. Ready-to-use, epoxy, or non-cemen-
titious grout will require a cleaning product
specific to the grout chosen. A penetrating
Congratulations your Thin Brick Project is Complete!
tile or stone sealer may be used for exterior
installations or those exposed to water. 10
ironrock.com | 1.888.325.3945 | [email protected]

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