How to replace a damaged or spalled brick

When a single brick has crumbled, flaked, or cracked through, it can usually be cut out and replaced. Done properly the repair disappears into the wall. Done badly it loosens the bricks around it.

What spalling is

Spalling is when the face of a brick flakes or pops off, leaving a rough, open surface. It happens when moisture gets into the brick and then freezes, expands, or carries salts that break it apart.

• Common on older soft bricks and anywhere water sits or splashes.
• Often a sign of a damp issue, not just a one off bad brick.
• Worth checking the cause, because a fresh brick in a wet spot will spall again.

How a brick gets replaced

The job is methodical. The aim is to remove the damaged brick without stressing its neighbours.

• Rake and cut out the mortar joints all around the brick.
• Break out the old brick carefully, often in pieces, so nothing else moves.
• Clean the opening back to sound brick and mortar.
• Match a replacement brick for size, colour, and texture.
• Bed it in fresh mortar, then point the joints to match the surrounding wall.

Matching is the part people underestimate. The right brick and the right mortar colour are what make the repair vanish.

Matching and finishing

Getting a close match on an older Melbourne home takes some hunting.

• Salvage yards and recycled brick suppliers are often the best source for period bricks.
• Mortar colour and joint style need to match the existing wall, not just the brick.
• One mismatched brick stands out more than the damage did, so it is worth getting right.

If you have a brick or two that have spalled or cracked, send us a clear photo and your suburb. We can tell you whether it is a simple swap or a sign of something worth looking at underneath.