Repair Cracked Brick, Block, or Stonework

A. Finished-Project Specification

Deliverable: one completed masonry-unit replacement, matched in size, color, texture, and finish to the surrounding masonry, set with full bed, head, and back-surface mortar coverage, surrounded by fully repointed joints matching the adjacent profile and color, with a documented crack-evaluation record, cavity-inspection findings, and a final classification confirming the repair remained within nonstructural scope.

B. Component and Material Schedule

Component	Quantity	Material	Preparation
Replacement unit	1 (or as approved for the replacement area)	Brick, block, or stone matching the existing unit's size, color, texture, and finish	Cleaned of dust, ice, and loose material; cut only per Chapter 10 where dimensional fitting is required
Bedding and repointing mortar	As required to fill the cavity and surrounding joints	Mortar type compatible with the existing masonry per Chapter 3 and Chapter 14 compatibility principles	Mixed in small batches sized to the repair area's working time
Cavity inspection materials	As needed	Clean water for rinsing; HEPA vacuum for dust removal	Staged before removal begins
Cure protection	1 set	Covers, damp cloths, or approved curing compound	Sized to the repair area and staged before mortar placement

C. Documentation Requirements

• Photographs: the crack before removal with a scale or crack-width gauge visible, the removed unit, the exposed cavity showing backing, ties, reinforcement, and flashing condition, and the completed repair.
• Crack Evaluation Record: completed in full before removal begins, including the final Cosmetic or Structural — Stop-Work classification.
• Cavity inspection findings: a written record of backing condition, tie or reinforcement condition, flashing condition, and any moisture found, with a note of any condition requiring professional referral.
• Referral record: for any condition meeting a stop-work criterion, the professional contacted and the date of referral.

D. Acceptance Standards

Check	Standard
Crack classification	Cosmetic: no measurable displacement, no stepped or horizontal pattern, no bulging, no proximity to a failed lintel or unstable foundation. Any of these present requires Structural — Stop-Work classification and professional referral
Cavity condition	Backing, ties, reinforcement, and flashing are sound and free of concealed defect; any concealed defect discovered halts the repair and is documented for referral before replacement proceeds
Unit fit	Replacement unit matches the surrounding masonry in size within the manufacturer's or matched-batch dimensional tolerance, and in color and texture within visual match at normal viewing distance
Mortar coverage	Full mortar coverage on bed, head, and back surfaces of the replacement unit, with no voids detectable by tapping or visual inspection of the joint face
Joint profile and color	Repointed joints match the adjacent joint profile and are visually consistent in color and texture at normal viewing distance
Alignment	Replacement unit is flush with the adjacent wall face within 1/8 inch (3 mm), measured with a straightedge spanning the repair and adjacent units
Recurrence check	No new displacement, cracking, or movement observed at the repair or immediately adjacent area during the final inspection

E. Crack Evaluation

1. Record crack location, orientation, width, displacement, length, moisture, age, weather, and prior repairs. Complete the Crack Evaluation Record before touching the wall.
2. Inspect foundations, lintels, openings, wall ends, roof loads, drainage, and movement joints. Note any of these located within the immediate vicinity of the crack.
3. Distinguish surface mortar cracking from unit cracking, stepped cracking, horizontal cracking, bulging, or displacement. Use the straightedge and level to check for displacement and out-of-plumb condition across the crack.
4. Stop work for active movement, wide or displaced cracks, failed lintels, bowed walls, retaining pressure, foundation movement, or chimney instability. Photograph the condition from a safe distance, record the classification as Structural — Stop-Work, and refer it to the responsible professional. Do not proceed to Step 5 for a condition classified Structural — Stop-Work.

F. Preparation and Unit Removal

1. Mark the approved unit-replacement area. Outline the single damaged unit and its immediately surrounding joints confirmed as Cosmetic in Step 4.
2. Establish silica, dust, falling-debris, and access controls. Stage HEPA vacuum, wet-cutting equipment where cutting is required, and falling-debris protection before removal begins.
3. Remove mortar around the damaged unit using controlled hand or power tools. Work from the joint inward, using hand chisels or a controlled rotary tool with wet or extraction attachment.
4. Avoid damaging adjacent units and reinforcement. Direct chisel force away from adjacent unit edges and any visible ties or reinforcement.
5. Remove the damaged unit in pieces if necessary. Break the unit into manageable sections rather than forcing an intact unit that risks damaging the cavity.

G. Cavity Inspection and Replacement

1. Clean the cavity and inspect backing, ties, reinforcement, flashing, and moisture. Vacuum debris with the HEPA vacuum and photograph the exposed cavity before proceeding.
2. Stop work if concealed support or water-management failure is discovered. Record any corroded tie, damaged flashing, unsound backing, or active moisture source found during cavity inspection, and refer it to a qualified professional before replacement proceeds.
3. Select a matching replacement unit. Confirm size, color, texture, and finish match against the Acceptance Standards table before setting the unit.
4. Prepare the cavity and replacement surfaces. Dampen the cavity where the mortar specification requires it and clean the replacement unit of dust or loose material.
5. Apply mortar to the bed, head, and back surfaces as required. Cover all bearing and joint surfaces of the replacement unit fully; do not rely on head-joint mortar alone.
6. Insert the unit without displacing adjacent masonry. Press the unit into place using steady, even pressure rather than forceful tapping that could disturb adjacent units.

H. Repointing, Cure, and Final Inspection

1. Pack all surrounding joints fully. Fill each joint around the replacement unit in controlled lifts, compacting each lift per the Chapter 14 repointing procedure.
2. Align the face and bond. Check the replacement unit's face alignment against the adjacent wall face with a straightedge before the mortar sets.
3. Tool joints to match adjacent work. Tool each joint when thumbprint hard, matching the adjacent joint profile.
4. Clean the repair. Brush loose crumbs and remove mortar smears from the unit face without smearing mortar across adjacent joints.
5. Protect and cure it. Cover the repair area per the cure-protection plan and protect it from rain, freezing, rapid drying, and impact for the required cure period.
6. Inspect unit fit, joint bond, color, profile, alignment, and recurrence of movement. Compare the finished repair against the Acceptance Standards table and the original Crack Evaluation Record.
7. Document diagnosis, replacement, and structural referral limits. File the completed Crack Evaluation Record, cavity-inspection findings, photographs, and any professional referral with the project's readiness and inspection records.