Laying reclaimed bricks: how to build an authentic wall

Why laying reclaimed bricks is different

A wall of reclaimed masonry bricks gains its character from differences in colour, texture, size and patina. Those same qualities require a little more attention during laying than completely uniform modern facing bricks.

Small dimensional differences can occur within one historical batch. Suction can vary too. Before starting, inspect and measure several bricks and match the mortar and working method to them.

The result does not need to be completely uniform. A well-built reclaimed brick wall can show the natural variations of the original material. Browse our completed projects using reclaimed materials for inspiration.

Step 1: choose a suitable reclaimed batch

The final wall’s appearance starts with the brick. Do not choose solely from one loose brick or photograph: inspect a representative part of the batch.

Our range includes handmade bricks, moulded bricks, IJssel bricks, Frisian yellow bricks and Groningen bricks. Each type and batch has its own dimensions, colour range and texture.

Before buying, check that enough material is available from the same batch for the entire project, including a suitable allowance for cutting, breakage and selection.

Step 2: determine dimensions, course gauge and header gauge

Old bricks are not always completely consistent in size. Measure several and use an average as the starting point for the masonry.

The course gauge is the average brick height plus the horizontal bed joint. The header gauge is the average brick width plus the vertical joint. Measuring several bricks side by side and stacked together accommodates small differences within the batch more effectively.

For background on historical formats, see our explanation of brick dimensions.

Step 3: choose the brick bond

The bond strongly affects both appearance and the required sorting. Stretcher bond, for example, needs a different distribution of visible faces and headers from English cross bond or English bond.

For traditional patterns with many visible headers, check beforehand how many good headers the batch contains.

Compare the possibilities in our explanation of different brick bonds.

Step 4: provide a suitable base or foundation

A masonry wall needs a sufficiently load-bearing, stable base. The foundation or support required depends on factors including the wall’s height, thickness, construction and location.

A small garden wall has different requirements from load-bearing masonry or a complete facade. If unsure, have a professional determine the structural arrangement, and follow the applicable drawings and specifications for a new build.

Step 5: prepare the reclaimed bricks

Reused bricks must be clean enough to lay again. Old mortar is therefore removed beforehand as far as possible. Read about cleaning mortar from reclaimed bricks.

Check visible faces during laying as well. Not every face of an old brick is equally attractive. Turning the best face outwards and distributing colours and nuances throughout the wall creates a calmer, more natural whole.

For a varied batch, mix bricks from different pallets or parts of the batch so colour differences do not appear as separate patches in the facade.

Step 6: match brick moisture to the mortar

Water absorption differs by brick type and batch. Very dry, high-suction bricks can rapidly draw moisture from mortar, while excessively wet bricks can also interfere with laying.

Assess the actual batch’s suction instead of routinely fully submerging every old brick. Suitable preparation depends on the brick, mortar, weather and laying method.

Step 7: select suitable masonry mortar

Do not use one universal mix ratio for every old brick. Suitable mortar depends on the brick, suction, application, joints, weather exposure and existing construction.

In restoration or when joining historical masonry, the existing mortar type can also be important. If unsure, have the mortar matched to the material and application.

Step 8: lay the first courses carefully

The first courses establish the dimensions for the rest of the wall. Use setting-out profiles and a bricklayer’s line, checking height, alignment and plumb regularly.

Distribute small dimensional differences gradually through the masonry. Do not try to force every historical brick individually into a rigid modern grid. An even handling of natural variation creates a more convincing result.

Step 9: distribute colours, textures and visible faces

This is one of the most important steps with reclaimed bricks. A varied batch can contain red, orange, yellow, dark or chalky shades. Laying pallet by pallet without mixing can produce unwanted colour patches.

Open several pallets at once and mix during laying. Regularly view the facade from a distance to spot where certain colours or textures are clustering.

Our projects show how different reclaimed bricks look in complete facades, extensions and garden walls.

Step 10: finish the joints to suit the brick

Pointing has a major influence on the result. The same old brick can look completely different with light, dark, recessed or prominent joints.

Choose joint colour, width and profile together with the brick and intended historical appearance. Read more about pointing mortar for old bricks.

Common mistakes when laying reclaimed bricks

Using all the bricks from one pallet consecutively

This can leave colour and texture differences as visible patches in the wall. Mix varied batches as much as possible during laying.

Assuming one exact brick size

Historical batches can have small dimensional differences. Measure several bricks and base the setting-out on a representative average.

Using a fixed mortar ratio for every reclaimed brick

Not every old brick has the same suction or application. Match the mortar to the actual batch and construction.

Ordering too few bricks

A historical batch is finite. If extra material is needed later, exactly the same batch may no longer be available. Include a sufficient allowance beforehand.

Looking only at the individual brick

A facade consists of thousands of bricks, joints and colour variations. Assess how the batch will work as a whole and look at completed examples where possible.

Reclaimed bricks for new builds, restoration and garden walls

Reclaimed masonry bricks have many applications. They are used to complete existing historical brickwork and for entire new homes, extensions, barns, garden walls and other new structures.

The contrast can be particularly interesting in new builds: modern construction and comfort combined with the immediate weathered appearance of old masonry. Read our detailed article on building with reclaimed bricks.

Our completed projects include Frisian yellow bricks, IJssel bricks, handmade bricks, moulded bricks and Groningen bricks.

Buying reclaimed bricks for your wall

Van Dillen Antieke Bouwmaterialen offers a large, continually changing range of reclaimed masonry bricks for new builds, restoration and renovation. Bricks are selected by batch and, where needed, cleaned of mortar and sorted for reuse.

If you already have drawings, a desired bond or the required facade area, we can help assess suitable batches and quantities. Browse the current range or visit us in Bolsward to compare batches side by side.