Mix mortar in batches
Mortar, rather than concrete, must be used in mosaics. There’s sand in the mixture but no gravel, so it’s smoother than concrete and adheres well to the stones.
To install a mosaic I work with small batches of mortar one bag at a time, covering a 3- or 4-square-foot area. Being organized is important because I have to work quickly. I never do this on hot, sunny days. Working on an overcast day or in the shade gives me approximately 20 minutes until the batch starts to set.
To prepare the mortar, I use a wheelbarrow and a hose with a spray nozzle. First, I add an inch of water to the wheelbarrow and then a bag of mortar mix. These come in 60- and 80-pound bags. When working with mortar, it’s a good idea to wear sturdy rubber gloves and a dust mask during mixing to keep from inhaling mortar dust. I stir the mix by moving a garden hoe back and forth, being sure to scrape the bottom so that all the mortar is moistened, and adding water as needed.
When a batch of mortar is the consistency of stiff pudding, I pour it on the layer of compacted gravel. I spread the mortar starting at an edge of the form. The mortar should be about a half-inch lower than the finished grade so that when the pebbles are pressed in, they will be at the desired surface height. Depending on the size of the stones, some mortar will be displaced, especially when the mosaic is flattened. So, when placing larger pieces, I usually scoop some mortar out.
I pay a lot of attention to how the stones fit together. I generally set smaller pebbles on edge so that more than half of the stone is set in mortar. It’s important that the stones be embedded well so they don’t dislodge later (slideshow photo #6). Wetting the stones before setting them helps the mortar adhere to them. Mosaics look best if the stones are spaced closely and there’s as little mortar as possible showing (slideshow photo #7). Using pebbles in contrasting colors makes a pattern more visible. I leave a margin of mortar along the edge of the area I’m working on to prevent pebbles near this edge from slumping before the mortar sets.
After I've embedded rocks into an area of wet mortar that's begun to set, I place a piece of 1/2-inch-thick contractor's-grade plywood over my work and step on it to press the pebbles to a level even with the top of the form (slideshow photo #8). Then I lift the plywood and check the mosaic again to make sure all the stones are well attached. I sometimes have to repeat this process until the mosaic is at the level I want it to be.
Once it’s level, I gently spray away any displaced mortar until that area of mosaic is clean (slideshow photo #9) and trim away any leftover margin of mortar with a pointed trowel, chisel, or small pick ax (slideshow photo #10). I spread this excess mortar over the bottom of the next area, then cover it with another batch of mortar as I continue the process of setting pebbles and flattening them with the plywood. For a large project, like a patio, I can leave a finished section and continue the project in a day or so.
The slower the mortar cures, the stronger it will be. As mortar dries, it contracts from the surface faster than it does on the inside. This can cause flaking and cracking, so it is a good idea to wet the surface of a curing mosaic frequently for a few days to prolong the drying process. If there’s a film of mortar on the pebbles after the mosaic dries, I usually remove it with muriatic acid, also known as hydrochloric acid. When this acid is wiped on the mosaic with a rag, it dissolves the mortar on the surface of the pebbles. I always make sure I wear adequate skin protection and a respirator when working with muriatic acid. I then rinse it away with water, which neutralizes the acid.
If a pebble in a mosaic gets dislodged later and I want to reattach it, I mix up a small amount of a polymer product called Thinset, which is used for setting tile. It’s acrylic-based and very sticky. Since Thinset is a different color than the mortar and will stand out, I use it sparingly and make sure to clean up any excess that oozes out of the hole of the replaced pebble.
In a world of asphalt and gray concrete, a beautifully constructed pebble mosaic will capture the attention of those who see it. People rarely pass by my house without stopping to admire the mosaics I’ve created here. There’s a magic about them that makes all that obsessive work worthwhile.