Using Reclaimed Brick: Sustainability and Character in Your Projects

Reclaimed brick has emerged as a compelling material choice for environmentally conscious construction, combining exceptional sustainability credentials with unmatched aesthetic character and historical resonance. This comprehensive guide explores the practical considerations, technical challenges, and design opportunities associated with incorporating salvaged brick into contemporary building projects.

The environmental case for reclaimed brick begins with embodied carbon considerations. New brick production is energy-intensive, typically generating 0.5-0.6 kg CO₂e per standard brick through clay extraction, firing at approximately 1,000°C, and transportation. By contrast, reclaiming existing bricks requires only the energy for careful demolition, cleaning, and transportation to the new site—typically reducing carbon impact by 80-95% compared to new production. For a modest residential project using 10,000 reclaimed bricks, this represents a carbon savings equivalent to not driving an average car for an entire year.

Beyond carbon reduction, using reclaimed brick eliminates the need for new clay extraction, preserving natural resources and landscape. The practice also diverts substantial material from landfill, where construction waste represents approximately 35% of total waste volume in most developed countries. This combination of conservation benefits makes reclaimed brick among the most environmentally sustainable building materials available, particularly valuable for projects seeking high ecological performance or certification under systems like LEED, BREEAM, or Living Building Challenge.

Sourcing strategies for reclaimed brick have evolved significantly as demand has increased. Specialized architectural salvage companies now offer carefully cleaned, sorted, and graded reclaimed bricks with detailed provenance information and performance specifications. These suppliers typically maintain substantial inventories categorized by type, age, region of origin, and condition, allowing more predictable specification and supply chain management. For larger projects, working directly with demolition contractors can secure specific brick types from scheduled demolitions, though this approach requires longer lead times and greater flexibility in design detailing.

Selection criteria for reclaimed brick must balance aesthetic preferences with technical requirements. Visually, consider the desired character—whether seeking the refined precision of Georgian facings, the industrial robustness of Victorian common brick, or the artisanal variation of handmade country brick. Technically, assess frost resistance (particularly important for exterior applications in cold climates), compression strength (critical for structural applications), and salt content (affecting long-term durability and appearance). Most reputable suppliers can provide basic performance characteristics for their inventory, while specialty testing laboratories can assess specific properties when required for demanding applications.

Design integration of reclaimed brick requires thoughtful approaches to accommodate its inherent variability. Diverse sizes in salvaged batches may necessitate adjustable joint thicknesses within a permitted range, rather than the rigid dimensional standardization typical in new construction. Color variations can be addressed through intentional blending across the façade, creating natural variation rather than attempting perfect uniformity. When combining reclaimed brick with new elements, consider transitional details that acknowledge material differences rather than attempting to disguise them—honesty of expression typically yields more successful results than simulation.

Mortar selection significantly influences both performance and appearance when working with reclaimed brick. Historic bricks typically perform best with lime-based mortars that offer appropriate flexibility and moisture permeability, preventing damage from thermal movement and allowing proper moisture management. For aesthetic integration, mortar color should generally complement rather than match the brick, providing subtle definition without overpowering the material's natural character. Many projects benefit from slightly recessed joints that emphasize brick texture while accommodating dimensional variations.

Construction considerations for reclaimed brick projects include several practical adjustments to standard practices. Brief masons on the specific handling requirements for older, potentially more fragile units. Establish realistic productivity expectations—working with reclaimed brick typically proceeds at 60-75% the pace of new brick construction due to additional sorting and selection during laying. Plan for slightly higher waste factors (typically 10-15% versus 5-7% for new brick) to accommodate unusable units discovered during construction. For critical projects, consider creating mockup panels to align expectations and establish acceptable variation parameters before full-scale implementation.

Cleaning approaches must respect the delicate patina that gives reclaimed brick much of its character. For onsite cleaning of newly laid reclaimed brickwork, minimize water use and avoid acidic cleaners that can damage historic brick surfaces. Instead, utilize pH-neutral detergents specifically formulated for historic masonry, applying with soft brushes rather than abrasive methods. For particularly valuable historic brick, consider dry cleaning methods such as compressed air and soft brushing, which preserve the material's surface character while removing construction dust.

Structural applications require particular attention when using reclaimed brick in load-bearing capacities. Engage structural engineers with historic materials experience early in the design process to establish appropriate testing protocols and safety factors. For significant structural elements, laboratory testing of compressive strength, absorption rates, and freeze-thaw resistance provides essential performance data. In many jurisdictions, building codes allow performance-based approaches to structural certification of non-standard materials when supported by appropriate engineering analysis and testing.

Special applications beyond standard walls can highlight reclaimed brick's distinctive character. Herringbone or basketweave patterns for garden paths showcase the material's aged texture, while brick fireplace surrounds benefit from the subtle color variations in reclaimed units. Feature walls incorporating salvaged brick from buildings with local significance create meaningful connections to place, particularly valuable in adaptive reuse projects or additions to historic structures. Incorporating selected bricks with maker's marks, date stamps, or other distinctive features as accent elements creates focal points with built-in historical narrative.

By thoughtfully addressing these considerations, designers and builders can successfully incorporate reclaimed brick into projects ranging from small residential renovations to major commercial developments. The resulting structures combine exceptional environmental performance with rich visual character and tangible connections to architectural heritage—qualities increasingly valued in an era of growing environmental awareness and appreciation for authentic building materials with genuine history and character.