Renovating the floor of an old barn begins with careful preparation. First, the existing surface is cleaned and leveled to ensure a stable foundation. Any loose debris, dust, or remnants of old flooring are removed. A compacted layer of gravel or sand may be added to improve drainage and support.
Next, lime mortar is prepared by mixing hydrated lime, sand, and water into a smooth, workable paste. This traditional mortar is breathable and flexible, making it ideal for historic buildings like barns, where moisture and movement are common.
Bricks are laid one by one, starting from a corner and working outward in rows. A generous layer of lime mortar is spread beneath each brick, and additional mortar is applied between them to bond the joints. The bricks are gently tapped into place with a rubber mallet to ensure they sit evenly and flush with the surrounding surface.
As the work progresses, a consistent pattern—such as herringbone, basket weave, or running bond—is maintained for both aesthetics and structural integrity. Excess mortar is wiped away, and the joints are smoothed with a pointing tool.
Once the entire floor is laid, it is left to cure slowly. Lime mortar sets gradually, allowing time for adjustments and ensuring a durable, long-lasting finish that complements the rustic charm of the old barn.
