Reclaimed brick has already spent decades, and often more than a century, as part of another building. Its worn edges, color variation, old mortar residue, irregular dimensions and occasional markings are part of what gives it character.
Reclaimed firebrick shares many of these characteristics but was originally manufactured for high-temperature environments such as fireplaces, kilns, furnaces and boilers. Whether selecting common brick or firebrick, understanding the material before installation is the best way to achieve a finished project that looks intentional and performs properly.
Before You Purchase
Determine the approximate square footage or brick count required before purchasing.
Reclaimed masonry is typically sold as a finite batch. Once a particular lot is gone, finding an exact match later may be difficult or impossible.
We generally recommend purchasing 10–15% additional material to account for cuts, breakage, sorting and future repairs. Projects involving complicated patterns, extensive cutting or unusually irregular material may require additional waste.
Before ordering, confirm:
- Approximate brick dimensions
- Full brick, thin brick or other format
- Common brick or firebrick
- Quantity available
- Interior or exterior application
- Wall, floor, fireplace or landscape application
- Whether the brick has been cleaned
- Amount of remaining mortar or surface residue
- Desired installation pattern
For large installations, we recommend having your mason, builder or architect review the material before purchase.
Expect Variation
Variation is an inherent part of reclaimed masonry.
Expect differences in color, dimensions, edge condition, surface texture, firing marks, chips, old mortar residue, weathering and manufacturer stamps or markings.
Reclaimed firebrick may also exhibit soot, carbon staining, heat discoloration and remnants of refractory mortar from its previous use.
These characteristics should be intentionally mixed throughout the installation rather than treated as defects. The mason should work from multiple pallets or stacks at the same time to distribute variation naturally across the project.
Measure the Actual Brick
Do not design around the nominal dimensions of modern brick and assume reclaimed material will match.
Older bricks were produced in many different sizes, and dimensions can vary even within the same batch.
The mason should have actual samples before finalizing openings, coursing, wall dimensions and mortar-joint sizes where those dimensions are critical. This is particularly important around doors, windows, arches and other architectural elements where coursing needs to align.
Cleaning & Preparation
Reclaimed brick may retain traces of old mortar, lime, dirt, soot or other surface deposits.
Loose material can generally be removed before installation, but aggressive cleaning should be approached carefully. Historic brick can be softer and more porous than modern masonry, and aggressive pressure washing, grinding, sandblasting or harsh chemical cleaners can permanently alter its surface.
Whenever a cleaning method is being considered, test it on a small group of bricks first.
For reclaimed firebrick being used indoors, make sure loose soot, dust and residue have been appropriately removed before installation.
The goal is not necessarily to make reclaimed brick look new. Some residue, staining and weathering are often an important part of its appearance.
Mortar Selection
Mortar should be selected for the brick being installed rather than simply using the strongest mortar available.
Many historic bricks are softer and more absorptive than modern brick. An excessively hard mortar can concentrate movement and stress within the brick rather than allowing the mortar joint to accommodate it.
For historic or particularly soft brick, a more compatible mortar may be appropriate. Firebrick exposed to high temperatures may require an appropriate refractory mortar rather than conventional masonry mortar.
The project architect, mason or qualified restoration professional should determine the appropriate mortar based on the actual brick, exposure and application.
Mortar color and joint profile also have an enormous visual impact on reclaimed masonry. We strongly recommend preparing a physical mortar mockup before the entire project is installed.
Mortar Joints
Reclaimed brick often benefits from a slightly more forgiving mortar joint than highly uniform modern brick.
Joint width can help absorb dimensional variation while maintaining consistent coursing. Common treatments include tooled, flush, struck, raked and intentionally overfilled or historically inspired joints.
There is no universally correct joint for reclaimed brick. The appropriate choice depends on the architecture, brick and desired appearance.
For significant installations, always approve a sample panel before proceeding.
Installation
Reclaimed brick should be installed by a mason familiar with traditional masonry and dimensional variation.
Depending on the application, installation may require consideration of:
- Structural backing
- Masonry ties or anchors
- Flashing
- Weep systems
- Drainage cavities
- Expansion and control joints
- Moisture management
- Appropriate mortar
- Proper support at openings
Reclaimed brick does not eliminate any of the water-management or structural requirements of a modern wall assembly.
The brick may be old. The wall behind it should still be designed and built correctly.
Exterior Applications
Not every reclaimed brick is appropriate for every exterior environment.
Historic brick varies considerably in density, porosity and water absorption. Brick originally used in a protected interior wall may behave differently from brick that spent a century exposed to weather.
For exterior projects, particularly those exposed to repeated saturation or freeze-thaw cycles, the suitability of the specific brick should be evaluated before installation.
Where performance is critical, additional testing may be appropriate.
Floors, Patios & Horizontal Surfaces
Both reclaimed common brick and firebrick can create beautiful floors, porches, patios, courtyards and other horizontal surfaces when appropriate for the application.
These installations require additional consideration of substrate preparation, finished floor thickness, moisture, joint width, cleaning, sealing, slip resistance and, for exterior applications, drainage.
Full-depth brick can create a substantial floor assembly. If floor height is limited, reclaimed thin brick or brick cut into flooring units may be more appropriate.
Confirm the complete floor assembly before construction begins.
Fireplaces & High-Heat Applications
Common reclaimed brick and reclaimed firebrick are not interchangeable in high-heat applications.
Firebrick, sometimes called refractory brick, was manufactured specifically to withstand repeated exposure to high temperatures. It was traditionally used in fireboxes, kilns, furnaces, boilers and other high-heat environments.
Do not substitute ordinary reclaimed building brick for firebrick simply because the brick is old or was previously located near a fireplace.
Reclaimed firebrick intended for direct exposure to flame or sustained high temperatures should be inspected for significant cracks, spalling or deterioration. The mason, fireplace manufacturer or project professional should determine whether the material and assembly are appropriate for the intended application.
Firebrick in a firebox should be installed with an appropriate refractory mortar where required by the fireplace design and applicable codes.
Unless specific testing or documentation is provided, reclaimed firebrick should not be assumed to carry the same certified temperature ratings or performance standards as newly manufactured refractory products. Where a particular rating or tested performance is required, the material should be evaluated before installation.
Sealing
Reclaimed brick does not always need to be sealed.
In some applications, leaving the brick unsealed allows it to retain its natural appearance and vapor permeability. In others, particularly interior floors or areas exposed to staining, a compatible penetrating sealer may be desirable.
Always test the proposed sealer on the actual material before widespread application. Sealers can change the color, sheen and moisture behavior of porous masonry.
Efflorescence & Moisture
White mineral deposits occasionally appearing on masonry are known as efflorescence.
Efflorescence occurs when moisture moves soluble salts through masonry and deposits them at the surface as the water evaporates. Its appearance can be related to the brick, mortar, surrounding materials or moisture entering the assembly.
Persistent efflorescence should be treated as a reason to investigate moisture movement rather than simply repeatedly cleaning the surface.
Good flashing, drainage and water management remain essential.
Order Enough the First Time
This is particularly important with reclaimed masonry.
A future batch may be similar, but it is unlikely to be identical.
If the project may eventually require repairs, additions or matching masonry, consider purchasing and storing additional brick from the original batch. A small reserve can be extremely valuable years later.
Choosing a Mason
Reclaimed brick rewards a good mason.
Look for someone comfortable working with historic masonry, reclaimed brick, firebrick and irregular materials, rather than assuming the material will install exactly like modern manufactured brick.
The mason should understand that the goal is not to force every brick into perfect uniformity. Good reclaimed masonry balances consistent craftsmanship with the natural irregularity of the material.
For significant projects, we strongly recommend constructing and approving a sample panel before full installation begins.
A Note From Green Pirogue
Reclaimed brick should look like reclaimed brick.
Worn corners, old mortar, firing variation, soot, maker's marks and differences from one brick to the next are evidence of the material's previous life. They are part of why we choose old masonry in the first place.
At the same time, old material deserves thoughtful installation. Mortar compatibility, water management, sorting and good masonry workmanship matter just as much with a hundred-year-old brick as they do with a new one.
Our goal is to help you understand the material before it reaches the jobsite. If you are considering reclaimed brick or firebrick for a project, we are happy to provide available dimensions, photographs and material information for review by your architect, builder or mason before purchase.
