This may be one of the hardest projects I've done at Project Hillside. On paper, it seems like a breeze. But, it is very physically demanding. Of course, I elected to haul all the materials ourselves to save money and it ended up taking an half day to get all the materials. We unloaded 762 brick by hand (3,048lbs total), unloaded 1.5 tons (3,000 lbs) of gravel base by hand, and unloaded all the sand (1,600 lbs) by hand. Grand total of all the weight moved by hand: 7,648lbs!
Once all the materials were unloaded we had to mark out a 15x11 foot area for the actual patio and dig it out 6 inches deep. That would give us a 4 inch packed gravel base, 1 inch sand base, and a little room on top so the bricks don't protrude above the ground. I laid out two large tarps and starting digging, throwing the dirt we were digging out on them. This would eventually be moved (by hand, yet again!) to the back of the garage and used when that area is leveled. Digging and moving all the dirt took a little over half a day.
Wheelbarrow by wheelbarrow I moved the gravel pack into the area, dumped it, and we did our best to pack it by hand. It took a lot of time, sore arms, and lots of hits with the tool to get it packed as good as we could.
Next, all the said was dumped in (I bought bag sand) and I used a rake to level it out, much like you would with concrete. The plan was to use two 1 inch pipes and a 2x4 to level the sand. Quickly, we both agreed that wasn't working. So, I did the best job I could to level it and leveled much smaller areas by hand as the bricks were laid.
Next, we laid out the edging. Since I didn't want ANY cuts in the bricks, it was a bit tedious to ensure the measures were spot on. Amber took the lead on this.
The idea was to have it slope, like a road, away from the house. I was able to get a bit of slope on it so it doesn't go directly into the house, but it isn't perfect. The back right corner slopes a little much, but I am going to live with it. Everyone loved the patio and anyone that complains, well, they can dig it up and go through this hell of doing it by hand themselves!
Laying the bricks was a VERY tedious job. I laid it, hit it with the mallet, and put my level on it to ensure it was right. Each row had a total of 40 bricks. We wanted to ensure the grout lines would line up (and I am pleased to report I did one hell of a job on that) and the edges were straight with the house. SUCCESS! It took me two days of laying brick. My knees would kill me and it was 90' with the sun baking me. One tip: Screw the mallet hammer to the actual grip. After about 200 bricks it just flies off. Evidently these things are simply glued. Laying the brick took much longer than I thought (folks told me it would take 3 - 5 hours). So, either I am extremely slow OR the fact that I leveled as I went, OR I took to many breaks .. whatever it was, it took 2 FULL days.
Once the brick was in, I tightened up the black edging a little and ensured it was still pegged down nicely.
Next, I bought 3 buckets of this Sacrete Sand Grout mix at Lowes for the grout between the bricks. You dump it on, brush it out, and mist it with water. Instead of just sand, it actually bonds the bricks. I was VERY pleased with this approach.
Finally, we had a finished product. I am going to put pea gravel in the back near the house to act like a french drain JUST in case we get one heck of a rain storm and water starts to puddle up (I doubt, but can't be to safe). We put the patio furniture on and the next day we had Hula @ Hillside. I smiled every time someone complimented it.
HGTV reports it would of cost us $4,000
I got away doing it myself just under $1,000
The entire time I cussed, got angry, and said how I would never do this again. I hit my thumb with the mallet and couldn't use it for a day, sun burn on my nose and entire neck, and my knees were bruised up. But, for a $3,000 savings, I'll do it again .. I certainly don't make $1,000/day which is what it could of cost in labor!
The pattern I was going to do - basket weave
Cost per brick
$19 for the Lowes rental truck .. now we had to unload by hand :(
Amber took the ground, I was on the truck
The piles were growing
Digging it
Spreading the base and getting ready to pack it
Now the cussing starts .. and I take no pictures while laying bricks ..
2 days later ..
I am very pleased
At the end of the project I had a Forest Gump like vision ..when he is running with hundreds of people following him for thousands of miles .. he turns around and simply says, "I think I will go home now". When I laid that last brick, well, it was just done .. This is my self portrait .. it doesn't quite show how tired I am.
The following day, Hula at Hillside for Amber's Birthday
Lessons learned:
1. Either have a few hands to help or rent a Bobcat to dig it out
2. Do not pickup the brick yourself, have it delivered
3. Do not pickup the gravel base yourself, have it delivered
4. Do not pickup the sand yourself, have it delivered
5. Plan 3 days, take your time
6. Ensure no kids are around, you will get angry multiple times
7. Ignore youtube videos .. these people make it look easy