- 1. Introduction
- 2. Manufacturing
- 3. Standards and codes
- 4. Brick types
- 5. Properties and tests (IS 3495)
- 6. Design and detailing
- 7. Common failures and remedies
- 8. QA and QC checklist
- 9. Brick bonds
- 10. Sample specification clause
- 11. BOQ lines
- 12. Method statement — brickwork
- Disclaimer
Purpose: consultant-ready guide to brick masonry. Use the TOC to jump to manufacturing, standards, properties and tests, design and detailing, failures, QA, bonds, spec, BOQ, and method statement.
1. Introduction
Burnt clay brick masonry is a ubiquitous walling system for load-bearing and infill walls. When executed correctly it provides structural performance, durability, fire resistance, and reasonable thermal mass.
2. Manufacturing
- Soil selection and testing: Sand:silt:clay balance. Organic matter < 1%. Control plasticity. Remove inert contaminants.
- Preparation and pugging: Uniform moisture content. Pug mill for consistent plasticity.
- Moulding: Hand-moulded or extrusion (wire-cut preferred for precision).
- Drying: Controlled 7–14 days in shade and ventilation. Avoid rapid drying.
- Burning: Clamp or Hoffman kiln at 900–1100°C to achieve vitrification without overfiring.
- Cooling and grading: Sort by color, sound (ring test), and size tolerance. Store dry on pallets.
3. Standards and codes
- IS 1077 — Common burnt clay building bricks.
- IS 3495 (Parts 1–3) — Testing bricks (compressive, absorption, efflorescence).
- IS 2212 — Code of practice for brickwork.
- IS 2250 — Masonry mortars.
- IS 1905 — Structural masonry design.
4. Brick types
Type | Description | Application |
First class bricks | Uniformly burnt, sharp edges, water absorption < 15% | Structural walls |
Second class bricks | Slightly over/under burnt, minor imperfections | Internal walls, plastered surfaces |
Fly ash bricks | Fly ash and lime | Sustainable, uniform finish |
Fire bricks | High alumina content | Kilns and chimneys |
5. Properties and tests (IS 3495)
Parameter | Test standard | Typical acceptance |
Compressive strength | IS 3495 Part 1 | ≥ 7.5 MPa typical for first class (specify project grade) |
Water absorption | IS 3495 Part 2 | < 20% (first class) |
Efflorescence | IS 3495 Part 3 | Nil to slight |
Dimensional tolerance | IS 1077 | ± 3 mm (L/W/H) |
Soundness | Ring test | Clear ring indicates acceptable |
Bulk density | — | ≈ 1800–1950 kg/m³ |
6. Design and detailing
- Wall thickness: 115, 230, 290 mm as per structural design.
- Joints: 10 mm nominal mortar joints; maintain consistency.
- Control joints: Provide every 6 m horizontally, near openings, corners, and material junctions. Width 10–12 mm with suitable sealant.
- DPC: Minimum 150 mm above external ground level; continuous at plinths.
- RCC integration: Use galvanized bonding mesh and starter bars or shear keys at junctions. Provide lintel and sill bands.
- Curing: Mist spray for a minimum of 7 days.
7. Common failures and remedies
Symptom | Likely causes | Diagnostic check | Remedial step |
Efflorescence | Soluble salts or rising damp | Salt test, moisture mapping | Remove salts, apply breathable repellent, fix DPC/drainage |
Rising damp at plinth | Missing/failed DPC | Moisture probe, visual staining | Retrofit DPC and improve drainage |
Vertical or horizontal cracks | Settlement, lack of movement joints, thermal movement | Crack mapping, tell-tales | Provide/enlarge joints, stitch as needed, underpin if structural |
Bulging walls | Poor bonding, inadequate support, moisture | Visual deflection | Rebuild section, install ties, improve mortar strength |
Hollow sounds under plaster | Poor key or weak suction control | Hammer sounding | Remove and re-plaster with bonding slurry and PMM |
8. QA and QC checklist
- MTCs for bricks, sand, and cement.
- Sand sieve analysis within Zone II (IS 383).
- Brick compressive strength test per batch.
- Mortar mix verification (1:6 or as specified) by weight.
- Joint thickness checks: 5 readings per 50 m²; mean 10 mm ± 2 mm.
- Wall plumb: ± 3 mm per 2 m.
- Curing log: start time, method, minimum 7 days.
- Pond test for wet areas: 72 hours without leakage.
9. Brick bonds
- English bond
- Flemish bond
- Rat-trap bond (hollow cavity improves thermal performance)
10. Sample specification clause
Supply and construct 230 mm thick brick masonry using first class burnt clay bricks in cement mortar 1:6 (1 cement : 6 washed sand), including scaffolding, raking of joints, DPC installation, lintels, and curing for 7 days. Comply with IS 1077, IS 2212, and IS 2250. Rate to include materials, labour, wastage, curing, and testing as per ITP.
11. BOQ lines
- Brick masonry 230 mm in CM 1:6 — unit m³
- Brick masonry 115 mm partition in CM 1:4 — unit m²
- DPC with bituminous felt 2 mm — unit m
- External cement plaster 20 mm (2 coats) — unit m²
- Flush pointing with polymer-modified mortar — unit m
12. Method statement — brickwork
- Scope and references: IS 1077, IS 2212, IS 2250.
- Materials and acceptance: MTCs, sample tests, sand FM and silt checks, cement checks, mortar 1:6 by weight.
- Execution: Layout and levels; plumb profiles every 3 m; full-bed laying; 10 mm joints; reinforcement as detailed; DPC; lintels and bearings.
- Finishing and curing: Rake joints; protect from weather; cure 7 days; QA checks.
- Handover and tests: Dossier with MTCs, test reports, photos, curing record, ponding test results.
Disclaimer
SpecX is a neutral, brand-agnostic resource based on standards and best practices. Cross-check with project requirements and local codes before finalizing specifications.