Brick Types: Pros & Costs

Brick Types: Pros & Costs

Main brick families (what they are)

• Solid Clay Brick – Traditional fired clay, full-bodied unit.
• Perforated/Hollow Clay Brick – Fired clay with cores/voids for lighter weight & better insulation.
• Large-Format Hollow Clay Blocks – Oversized perforated blocks (e.g., 25–38 cm) for fast walling.
• Clinker/Engineering Brick – Very dense, low-absorption clay bricks for strength and harsh exposure.
• Calcium Silicate (Sand–Lime) Brick – Sand, lime, water, autoclaved; crisp arrises, high dimensional accuracy.
• Facing / Architectural Brick – Selected for visible façades (textures, colors, glazing).
• Refractory (Fire) Brick – High-alumina/fireclay for high temperatures (stoves, fireplaces).
• Brick Slips (Veneers) – Thin facing cuts for cladding; not structural.

Where each fits best

• Solid Clay: Heritage builds, loadbearing walls, robust partitions.
• Perforated/Hollow Clay: General walling with better thermal performance and lower weight.
• Large-Format Blocks: Fast structural walls with improved insulation and fewer joints.
• Clinker/Engineering: Plinths, retaining walls, high traffic/freeze–thaw/exposure zones.
• Sand–Lime: Precise masonry, thin joints, excellent for crisp façades and interiors.
• Facing/Architectural: Visible façades, feature walls, color/design consistency.
• Refractory: Fireboxes, chimneys, ovens.
• Brick Slips: Lightweight façade upgrades over suitable substrates.

Pros & cons (at a glance)

Solid Clay

• + High mass & durability; good sound insulation; classic look.
• − Heavier, slower to lay; lower thermal resistance than hollow types.

Perforated/Hollow Clay

• + Lighter, better thermal performance; faster laying than solid.
• − Lower point-load capacity; fixings require proper anchors.

Large-Format Hollow Blocks

• + Fast build, fewer thermal bridges, good U-values with infill renders.
• − Needs trained crews, careful chasing/services planning.

Clinker/Engineering

• + Very low water absorption, high strength, excellent freeze–thaw & salt resistance.
• − Harder to cut; higher material %; limited insulation value.

Calcium Silicate (Sand–Lime)

• + High accuracy, flatness, good acoustic mass; clean joint lines.
• − Higher absorption than clinker; needs good detailing in wet/frost zones.

Facing / Architectural

• + Wide aesthetics (textures, glazed, handmade); durable façade finish.
• − Cost premium; color batching/coordination needed.

Refractory

• + Heat resistant; dimensionally stable at high temps.
• − Niche use; special mortars required.

Brick Slips

• + Lightweight cladding, quick makeover, minimal load on structure.
• − Not structural; relies on substrate/adhesive system.

Benefits (owner outcomes)

• Longevity & low upkeep (most fired clays, clinker).
• Thermal & acoustic comfort (mass + cavity/insulation design).
• Fire safety (all mineral masonry).
• Aesthetics & resale (facing/architectural bricks, authentic textures).
• Speed (large-format hollow blocks reduce program time).

Cost guide (percentages only; baseline = standard perforated/hollow clay brick = 0%)

(Material + typical laying effort per m² of walling; varies by size, grade, finish, and site conditions.)

• Solid Clay: +10–30% vs baseline
• Large-Format Hollow Clay Blocks: +10–25% materials, but −10–25% labor (faster build) → overall often −5–10% vs baseline on big areas
• Clinker/Engineering: +30–80% vs baseline
• Calcium Silicate (Sand–Lime): +10–35% vs baseline
• Facing / Architectural (standard): +20–60% vs baseline
• Facing (handmade/glazed/special): +60–150% vs baseline
• Refractory Bricks: +40–120% vs baseline (niche supply)
• Brick Slips (façade systems): materials +20–70% vs baseline; installation +10–40% (substrate prep, rails/adhesives)

Lifecycle / maintenance over ~15–20 yrs

• Clinker/Quality Facing: −10–25% vs baseline (least upkeep)
• Large-Format Blocks (rendered): 0–10% vs baseline (render drives upkeep)
• Sand–Lime (rendered/painted): 0–10% vs baseline
• Handmade/glazed specials: +5–15% vs baseline (cleaning, joint care)

Performance notes

• Thermal: Hollow/large-format > solid/clinker (at equal thickness). Add cavity insulation for best results.
• Acoustic: Mass matters—solid clay & sand–lime excel; hollow types improve with plaster both sides.
• Moisture/frost: Clinker/engineering best in splash zones; use DPCs, drips, and breathable details.
• Fixings: Use anchors rated for hollow cores when needed; pre-plan heavy loads.
• Mortars & joints: Match mortar class to brick type; consider thin-joint systems for sand–lime/large-format blocks.

Risks & how to avoid them

• Efflorescence: Salts migrating to surface. Fix: correct DPCs, breathable design, gentle cleaning.
• Spalling in freeze–thaw: Wrong brick in severe exposure. Fix: choose low-absorption/clinker grades.
• Thermal bridges at lintels/sills: Fix: thermal breaks, insulated lintels, proper cavity closers.
• Color batching mismatch (facing): Fix: order one batch; blend pallets on site.
• Services chasing in hollow blocks: Fix: follow manufacturer limits; avoid over-chasing load paths.

Quick choice guide

• Everyday structural walls, balanced cost/performance: Perforated/Hollow Clay
• Fast program, improved thermal, fewer joints: Large-Format Hollow Blocks
• Harsh exposure, plinths, durability first: Clinker/Engineering
• Crisp geometry, acoustic mass: Calcium Silicate (Sand–Lime)
• Premium façade look: Facing/Architectural
• Lightweight façade upgrade: Brick Slips