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Spalled brick repair? Anyone used this?

ChasingtheWelshdream
ChasingtheWelshdream Posts: 912 Forumite
Part of the Furniture 500 Posts Name Dropper Combo Breaker
Hi folks,

I am currently preparing some brickwork for repointing with lime.  

Unfortunately, some numpty previously repointed with cement and then painted with some plasticky-type paint, (I’ve spent hours removing as much as possible) but we have lots of badly spalled bricks, some of which are shaped/specials.

Its the plinth below the dpc, so there’s not a huge area, but it is unsightly.

The wall will be repainted (I splurged on highly breathable paint from Ty Mawr, don’t worry), but I’m pondering what to do with the damaged bricks.

Unfortunately replacing them is not an option at the moment, but we may do so as part of a bigger scheme of works in a few years.

My main concern is to prevent further damage. I could just point and paint, but I’ve also seen this product.

Has anyone used it? Or could comment on the suitability? Breathability is my most pressing concern.

https://steadfastspl.com/product/total-wall-care-brick-repair/?gclid=EAIaIQobChMIxrzZk9Dq8gIVB-ztCh3wHA4gEAAYASAAEgLmq_D_BwE
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Comments

  • As an aside, when we do get around to doing a proper job and replacing the bricks, is replacing ‘plinth’ bricks any harder than replacing a bog standard rectangle?
  • stuart45
    stuart45 Posts: 4,587 Forumite
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    I would use lime mortar to repair the bricks if it's going to be painted. That mix is expensive and really designed to match the colour of the face bricks. Replacing a plinth brick is straight forward, although plinth headers take a bit more cutting out.
  • ChasingtheWelshdream
    ChasingtheWelshdream Posts: 912 Forumite
    Part of the Furniture 500 Posts Name Dropper Combo Breaker
    edited 6 September 2021 pm30 5:33PM
    Thank you, that’s really helpful. 

    Would it be the same mortar mix as for the pointing? We will probably go for a couple of ready mixed bags from Ty Mawr as we do not need a huge amount and they are local for collection.

    Or would it be a different mix?

    I know it’s a bodge but I’m hoping for the repaired bricks to last 2-3 years and then do it all properly. Does that sound likely?

     (Obvs the pointing will be done properly, but as so many of the angled plinths are ruined I just do not have the time/energy this year)


  • stuart45
    stuart45 Posts: 4,587 Forumite
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    As it's only a thin face you will be putting on some of the bricks, you might be better using a bonding agent and a sand/cement mortar. They look quite a hard brick which won't be really breathable anyway. 
    As long as the joints are lime being the main issue.
  • ChasingtheWelshdream
    ChasingtheWelshdream Posts: 912 Forumite
    Part of the Furniture 500 Posts Name Dropper Combo Breaker
    edited 6 September 2021 pm30 5:58PM
    Thanks. What I’m quite confused about is how these ones in particular have spalled. 

    On one side there has been definitely been cement repointing. But on this area, the mortar is incredibly soft, almost sand-like. It scrapes out so easily I had wondered if it was lime, but it hardly fizzes at all when I put a bit in vinegar.

    And yet some bricks have crumbled really badly, at points the whole face split off as I scraped the loose paint. 

    So I assume the paint has caused the damage. I’m on the fence with the mortar.

    The adjoining house has no such issues. The only difference is the plinth is unpainted.

    My main consideration at the moment is preventing any further damage 
  • stuart45
    stuart45 Posts: 4,587 Forumite
    Sixth Anniversary 1,000 Posts Name Dropper
    Even engineering bricks can spall in time. Some will have very minor cracks from the kiln which can hold a small amount of moisture. They do also absorb a small amount anyway, though less than 4%. Paint will hold this in and causes problems with the constant freeze/thaw over the years.
  • Thank you, great explanation!
  • Hi Stuart,

    I just wondered what mix you would recommend to repair the bricks as above? Pretty please? 

    Thanks!
  • stuart45
    stuart45 Posts: 4,587 Forumite
    Sixth Anniversary 1,000 Posts Name Dropper
    If I was doing the job, I would give the area a bit of a wire brushing, then put on a bonding agent of SBR/cement mix.
    Then for the thin parts 3/1 silver sand/cement mix, and the deeper parts a 4/1 coarser sand/cement.
    However I do have all these materials to hand, so if you have to buy them all for just a few small repairs it would be cheaper to use the repair kit you first thought about.
    Otherwise as its only a repair for a few years before you replace the bricks, if you already have just the sand and cement around you could use a 4/1 mix which would probably last the distance. 
  • Thanks, that’s really helpful as I am tackling this next bit tomorrow.

     I don’t have silver sand but the builders merchant is only 5 mins away so no problem getting some I hope.

    The other reason we’re not replacing the plinth angled wotsits right now, is the gas pipe from the meter is fixed along the top of them for 3/4 the length of the wall. At some point we will move the boiler and then the pipe can be re-routed, but for now we don’t want to risk damaging the pipe in any way.

    So damage limitation for 3-4 years is the plan at the moment. And having it look semi-decent in the interim.

    Thank you ever so much!
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