The Ultimate Guide to Bricks

18th Nov 2022 -

Brick manufacturing has developed to embrace innovative technologies and sustainable practices. In this comprehensive trade guide, we'll explore how engineering and facing bricks continue to evolve in modern construction. 

We discover emerging trends like 3D printed and smart bricks and equip you with tips for achieving high-quality brickwork. Also, you'll gain key insights into brick wall insulation and brick waterproofing techniques.

• What is the History of Bricks in Construction?

• What Are the Most Common Types of Brick?
• How do Brick Styles Differ Across the UK?
• 7 Top Pro Techniques on How to Cut Brick
• Advanced Methods on How to Waterproof Brick Structures & Integrate Insulation
• What Are the Emerging Trends of Bricks?
• Shop Superb Bricks for All Construction Projects

What is the History of Bricks in Construction?

You might be surprised to learn that bricks have been a cornerstone of construction for thousands of years. The earliest bricks date back to around 7000 BCE and they were made from mud and dried in the sun. 

Brick-making techniques later advanced with fire bricks becoming commonplace around 3000 BCE. This method produced stronger, more durable bricks. Cultures from ancient Mesopotamia (Iraq, Turkey, Kuwait and Syria) to Rome refined brick-making processes.

In the 18th century, the Industrial Revolution brought mechanised brick-making. This led to standard brick dimensions (215mm x 102.5mm x 65mm) and more efficient production.

What Are the Most Common Types of Brick?

You've likely seen various brick types, each suited for specific applications. Here are the most common brick types you should be familiar with. 

• Clay Bricks: Widely referred to as facing bricks, you'll find these versatile bricks in many structures. They're made from clay and shale, fired at high temperatures (1,000-1,100°C). Clay bricks have been used since ancient times and remain popular for their durability.
  Composition: 50-60% sand; 20-30% clay; 2-5% lime; 5-6% iron oxide
• Concrete Bricks: These are your go-to for load-bearing walls and foundations. Made from cement, sand and aggregates, concrete bricks offer excellent strength. They've been widely used since the early 20th century, gaining popularity for their consistency
  Composition: 1 part cement; 2-3 parts sand; 1-2 parts aggregate (gravel or crushed stone)
• Engineering Bricks: When you need high strength and low water absorption, turn to engineering bricks. They're categorised as either Class A or B and made from specially selected clays, fired at extremely high temperatures (over 1,000°C). These bricks have been used since the industrial revolution for demanding applications like retaining walls
  Composition (depending on Class A or B): 65-75% sand; 20-30% clay; 1-3% lime; 4-7% iron oxide
• Fly Ash Bricks: You'll appreciate these eco-friendly options made from industrial waste products like fly ash. They've gained traction since the late 20th century. Fly ash bricks are lightweight and offer good insulation properties
  Composition: 50-60% fly ash; 32-40% sand; 8-10% lime; 1-2% gypsum

How do Brick Styles Differ Across the UK?

As a bricklayer, you'll encounter various regional traditions in brick architecture. The below list covers the most distinctive styles. 

London Stock Brick

You'll find this yellowish-grey brick throughout London and southeast England. London Stock Brick is made from clay mixed with ash, giving it a unique colour and texture. These bricks were widely used during the Georgian and Victorian eras.

Red Norfolk Brick 

In East Anglia, you'll see distinctive red bricks made from local clay. They're known for their durability and rich, warm colour. Many historic buildings in Norfolk and Suffolk showcase this traditional brick.

Staffordshire Blue Brick

If you're working in the Midlands, you might use Staffordshire Blue Bricks. They're extremely hard and durable, often used for engineering purposes. The colour comes from the high iron content in local clay.

Accrington Brick

In Lancashire, you'll encounter exceptionally strong, dense bricks. They're known for their distinctive red colour and were used in iconic structures like Blackpool Tower. Their durability made them popular for industrial buildings.

Fletton Brick

You'll find Fletton Bricks throughout much of England, especially in the Midlands and South. They're made from lower Oxford clay and have a distinctive "frog" (indentation) on 1 side. Flettons were widely used in 20th-century housing construction.

Cotswold Brick

In the Cotswolds region, you'll likely come across distinctive honey-coloured Cotswold Bricks made from local Jurassic limestone. These bricks complement the famous Cotswold stone buildings. They're known for their warm tones and are often used in conservation areas to maintain regional character.

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7 Top Pro Techniques on How to Cut Brick

Mastering advanced cutting brick techniques sets your work apart from standard construction practices. These methods go beyond basic cuts, allowing you to tackle complex projects with precision. Let’s discover these 7 approaches to improve your skills. 

1. Water cooling for precision cuts

Attach a water feed to your circular saw or table saw with a diamond blade. Adjust the water flow to provide a steady stream over the blade. Start the saw before contacting the brick, then guide it through steadily. Keep the water flowing throughout the cut. This reduces dust, prevents overheating and results in cleaner cuts.

2. Plunge cutting

This involves your knowledge of how to drill into brick. Mark your cut line clearly and drill holes at the corners using a masonry bit. Set your circular saw's depth to match the brick thickness. Start the saw, then slowly lower it onto the brick at 1 hole. 

Guide it steadily to the next hole. Repeat for all sides of the opening and clean up corners with a chisel if needed.

3. Kerf cutting for curved walls

Use a circular saw with a diamond blade as your brick-cutting tool. Set the depth to about ¾ of the brick's thickness. Make parallel cuts about 3mm apart along the brick's face. Space cuts closer for tighter curves and be careful not to cut through completely. Soak the brick in water before laying it to increase flexibility.

4. Angle grinding for custom shapes

Sketch your desired shape on the brick. Start with a coarse diamond blade on your angle grinder. Work in stages, removing material gradually and switching to a finer blade for finishing. Be sure to use both hands on the grinder for better control.

5. Brick splitting for a rustic look

Score a line around the brick where you want to split it. Place the brick on a solid surface with the scored line facing up. Position your bolster chisel on the score line and strike it firmly with a club hammer. If it doesn't split cleanly, use the chisel to clean up the edges.

6. Combination cutting for complex shapes

Start by making straight cuts with a circular brick-cutting saw where possible. Use an angle grinder to refine curves and angles. For intricate details, switch to a cold chisel and hammer. Work slowly and check your progress against your template frequently. Clean up any rough edges with a rubbing stone.

7. Core drilling for circular openings

Mark the centre of your desired hole and attach the core bit to your drill. Use a drill stand for stability if available. Start drilling into the brick slowly and increase the speed once the drill bit has created a stable starting point. Apply steady pressure and keep the drill at a 90° angle to the brick surface. 

Advanced Methods on How to Waterproof Brick Structures & Integrate Insulation

Upgrading your skill set for insulating and waterproofing bricks can greatly boost the performance of brick structures. Here, we detail advanced methods of waterproofing and insulating solid brick walls to build more energy-efficient and moisture-resistant buildings.

Aerogel blanket integration

You'll find aerogel blankets offer superb insulation without adding bulk. Measure and cut the blankets to fit precisely between brick layers. Apply a thin adhesive layer to the brick surface and place the aerogel blanket, ensuring it's flush with the brick edges. 

Press gently to secure, then continue the usual process of how to lay bricks. This provides excellent thermal performance in thin profiles, ideal for retrofitting historic buildings. 

Breathable waterproof membranes

To apply waterproof membranes, first ensure the brick surface is clean and dry. Mix the membrane solution according to the manufacturer’s instructions. Use a roller or low-pressure sprayer to apply evenly, starting from the bottom and working up. 

Ensure complete coverage, paying extra attention to joints and corners. Allow each layer to dry before applying further coats. Membranes allow moisture to escape, prevent water ingress, reduce the risk of frost damage and improve indoor air quality.

Vacuum insulated panels (VIPs)

When installing VIPs in cavity walls, handle them with care to avoid punctures. Measure the cavity space and order custom-sized panels if necessary - it’s recommended you wear gloves to protect the panel surface. Apply an adhesive to the wall in a grid pattern. 

Carefully place each panel, ensuring they fit snugly without gaps. Use thermal bridge-breaking fasteners like composite anchors or plastic sleeve screws if added support is needed. This achieves high R-values (thermal resistance) in limited spaces.

Nanotechnology-enhanced waterproof coatings

Before applying nanotech waterproof coatings like silica-based solutions, thoroughly clean and dry the brick surface. Mix the nanotech solution and use a low-pressure sprayer to apply the coating, maintaining a consistent distance from the wall. 

Work in small sections, ensuring complete coverage and pay extra attention to mortar joints and cracks. Apply a second coat after the specified drying time for optimal protection. This invisible layer delivers water-repellent properties and durability.

Adding phase change materials (PCM)

To introduce PCMs, you'll first need to select a compatible mortar or plaster mix. Carefully measure the recommended amount of PCM capsules (typically 5-30% of the mix weight). Gradually add the capsules to your mix while stirring continuously. 

Apply the PCM-enhanced mortar or plaster to interior brick walls. Smooth the surface carefully to avoid damaging the capsules. This technique improves thermal mass. 

Capillary active internal insulation

When applying capillary active insulation, thoroughly clean the interior brick surface. Choose either a specialised lime-based plaster or a mineral foam board. If using plaster, apply it in thin layers, allowing each to set partially.

For boards, apply adhesive in a full-surface bond, then press the boards firmly against the wall. Ensure there are no air pockets behind the insulation and finish with breathable paint. Overall, this manages moisture effectively and prevents condensation issues. 

Thermal bridge breaking anchors

When using thermal bridge breaking wall ties, follow a similar process to standard tie installation. Work out the required number and spacing of ties based on your wall design. As you build up your layers of brick, insert the thermal bridge breaking ties at intervals (450mm horizontal; 900mm vertical). 

Ensure the ties are pushed fully into the mortar bed and are level. When laying the inner leaf (inner cavity wall layer), make sure the ties are properly embedded. Use a cavity board to keep insulation pushed back against the inner leaf. This technique limits heat loss through traditional weak points.

What Are the Emerging Trends of Bricks?

Currently, the industry is experiencing a development in brick construction, with sustainability and technology at the forefront. Here are the key emerging trends you'll need to think about.

• Reclaimed and recycled bricks: You'll likely work with eco-friendly bricks sourced from demolition sites or made from recycled materials regularly. Expect to develop skills in preparing reclaimed bricks for reuse in new projects.
• Green manufacturing: Bricks produced using renewable energy and waste materials will be mainstream. In the future, you may need to familiarise yourself with types of sustainable bricks that have different properties. 
• 3D printed bricks: You'll come across more complex brick shapes and custom designs. Prepare to adapt your laying techniques for uniquely shaped units and operate small-scale 3D printers on-site for custom pieces.
• Smart bricks: You may need to learn how to install tech-integrated bricks. Work on the appropriate skills to troubleshoot and maintain these elements.
• Bio-based and living bricks: You'll work with bricks that have unique properties like air purification or self-healing. Expect to learn how these bricks work with the environment over time.
• Interlocking and dry-stacked systems: Mortarless systems may become frequent. Develop quick assembly methods and learn how they affect performance.