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Brickwork & Masonry Quality Standard

Comprehensive Standard Operating Procedure for brickwork and masonry construction ensuring structural integrity, safety compliance, aesthetic finish, and quality workmanship as per design specifications and IS codes.

Duration: 5-14 days Team: 4-8 workers Risk Level: Medium Validity: All Projects

1. Purpose

To establish a standardized procedure for brickwork and masonry construction ensuring structural integrity, safety compliance, aesthetic finish, and quality workmanship as per design specifications and Indian Standards (IS codes).

2. Scope

This procedure applies to all brickwork and masonry construction activities including brick/block laying, mortar preparation, jointing, pointing, cleaning, and curing for walls, partitions, and other masonry elements in civil construction projects.

3. IS Code References

Aspect IS Code Description
Brickwork Practice IS 2212:1991 Code of Practice for Brickwork
Masonry Mortars IS 2250:1981 Code of Practice for Preparation and Use of Masonry Mortars
Clay Bricks IS 1077:1992 Common Burnt Clay Building Bricks - Specification
Concrete Masonry IS 2185:2005 Concrete Masonry Units Specification
Brick Testing IS 3495:1992 Methods of Tests of Burnt Clay Building Bricks
Sand for Mortars IS 2116:1980 Specification for Sand for Masonry Mortars
Aggregates IS 383:2016 Specification for Coarse and Fine Aggregates
General Concrete IS 456:2000 Plain and Reinforced Concrete - Code of Practice

4. Responsibilities

Site Engineer

Oversees overall process & ensures compliance with specifications

Mason Supervisor

Leads masonry team & ensures quality workmanship

Safety Officer

Ensures safety protocols are followed at all times

Masons & Helpers

Execute masonry work & material handling operations

Quality Inspector

Conducts material and workmanship quality checks

Material Manager

Ensures timely availability of quality materials

5. Materials & Equipment

Bricks/Blocks

Clay bricks (IS 1077), AAC blocks as per specifications

Mortar Materials

Cement, sand, water (1:4/1:6 ratio as per IS 2250)

Hand Tools

Trowel, plumb bob, spirit level, line & pins

Mixing Equipment

Mechanical mixers, mixing pans, buckets

Scaffolding

Secure platforms for height work as per IS 4013

Additives

Waterproofing agents or other approved admixtures

Water

Clean potable water free from impurities

Testing Equipment

Compression testing machine, water absorption test kit

6. Column-Masonry Interface Quality Standards

A
Column Preparation for Masonry
  • Verify column surface is rough and clean for good bond
  • Check column plumb within tolerance (±5mm in 3m height)
  • Ensure proper marking of masonry wall centerline on column
  • Verify column concrete strength (min 85% of design strength)
  • Check for any defects like honeycombing requiring repair
B
Wall-Column Connection Details
  • Install wall ties or MS connectors as per structural drawing
  • Verify connector spacing (typically every 5-6 courses)
  • Ensure proper embedment depth in column (min 75mm)
  • Check wall tie extension into masonry wall (min 100mm)
  • Apply bonding agent at column-masonry interface if specified
C
Quality Control Checks
Parameter Acceptance Criteria Testing Method
Wall-Column Alignment ±5mm deviation from centerline Plumb bob, spirit level
Connector Embedment Min 75mm in column, 100mm in wall Visual inspection, measurement
Joint Thickness 10mm ± 2mm Joint gauge, measurement
Bond Pattern As per approved drawings Visual inspection
Mortar Fill 100% filled joints Visual inspection

7. Step-by-Step Procedure

1
Site Preparation & Material Inspection
  • Verify foundation/base is level and clean
  • Check for correct dimensions as per drawings
  • Ensure proper curing of foundation
  • Check quality of bricks/blocks (dimensions, cracks, strength)
  • Verify brick uniformity and color consistency
  • Test compressive strength (min. 3.5 N/mm² for common bricks)
  • Perform water absorption test (should be 15-20%)
  • Store bricks/blocks on flat, clean surface
  • Protect from direct contact with ground moisture
  • Cover with tarpaulin to protect from rain and extreme weather
  • Stack cement bags on raised platform, away from walls
  • Soak bricks for 2-3 hours before use
  • Drain excess water before placement
  • Ensure surface is damp but not dripping wet
2
Setting Out
  • Transfer layout from drawings to the working area
  • Mark corner points and wall lines using chalk line
  • Verify diagonal measurements for squareness
  • Check overall dimensions match design drawings
  • Fix corner profiles/masonry profiles at corners
  • Set up profiles 1-2m away from actual corner
  • Mark brick courses on the profile boards
  • Ensure profiles are stable and accurately positioned
  • Set up string lines between profiles for alignment
  • Verify horizontal level using spirit level
  • Check plumb at all corners and wall junctions
  • Mark door and window openings according to drawings
  • Clear the working area of debris and obstacles
  • Ensure adequate space for material movement
  • Set up masonry work platform if required
  • Verify proper drainage to prevent water accumulation
3
Mortar Preparation
  • Mix cement and sand in specified ratio (1:4 for structural, 1:6 for non-structural)
  • Use mechanical mixer for consistent quality if available
  • Measure materials by volume using gauge boxes
  • Record mix proportions for quality control
  • Mix dry ingredients thoroughly until uniform color
  • Add water gradually to achieve workable consistency
  • Mix for minimum 3 minutes to ensure homogeneity
  • Test consistency with mason's trowel (should form cone without slumping)
  • Add waterproofing compound if required as per manufacturer's specifications
  • Incorporate plasticizers or bonding agents if specified
  • Ensure thorough mixing after adding any additives
  • Record quantities of additives used
  • Prepare in batches to avoid setting before use (use within 30 minutes)
  • Do not retemper mortar that has begun to harden
  • Protect fresh mortar from direct sunlight and strong winds
  • Verify mortar consistency through slump test periodically
4
Laying First Course
  • Clean and moisten the foundation surface
  • Apply mortar bed on the prepared base (10-15mm thick)
  • Ensure uniform thickness of mortar bed
  • Check level before proceeding with brick laying
  • Lay bricks at corners first (quoins) to establish reference points
  • Check alignment with string line and levels
  • Build up 3-4 courses at corners to establish leads
  • Verify corner plumb with plumb bob or spirit level
  • Lay bricks between corner leads following string line
  • Ensure level using spirit level
  • Tap bricks gently to proper position with trowel handle
  • Maintain consistent joint thickness (10mm)
  • Check alignment frequently using straight edge
  • Verify level of first course at every 3-4 bricks
  • Ensure frog (depression) faces upward where applicable
  • Remove excess mortar from joints and faces
5
Building Up Courses
  • Follow specified bond pattern (stretcher, English, Flemish)
  • Maintain half-brick overlap for stretcher bond
  • Ensure header courses correctly placed for English bond
  • Verify pattern consistency throughout the wall
  • Apply mortar bed for horizontal joints (10mm thick)
  • Apply mortar to brick ends for vertical joints
  • Check vertical joints are staggered properly (minimum 1/4 brick)
  • Ensure joints are fully filled with mortar
  • Maintain plumb using plumb bob or level every 3-4 courses
  • Check course height at regular intervals
  • Verify wall is straight using straight edge
  • Adjust string line upward as courses progress
  • Install wall ties where specified (every 5-6 courses)
  • Place horizontal reinforcement as per drawings
  • Embed reinforcement fully in mortar
  • Ensure minimum 15mm mortar cover over reinforcement
6
Jointing & Pointing
  • Allow mortar to become thumbprint hard
  • Remove excess mortar from joints
  • Clean brick faces with soft brush
  • Rake joints to specified depth if required (10-15mm)
  • Prepare pointing mortar (1:2 cement:sand ratio)
  • Use fine sand for smoother finish
  • Add color pigment if specified
  • Mix to slightly stiffer consistency than laying mortar
  • Fill joints completely with pointing mortar
  • Finish joints as specified (flush, recessed, weathered)
  • Ensure consistent joint appearance throughout
  • Tool joints at correct time (semi-dry state)
  • Clean face of brickwork thoroughly
  • Remove mortar smears before hardening
  • Brush joints lightly to remove loose particles
  • Protect newly pointed work from rain and sun
7
Openings & Lintels
  • Mark openings as per drawings
  • Install temporary supports/formwork
  • Maintain specified dimensions for doors and windows
  • Check openings for square and plumb
  • Prepare bearing surfaces (min. 15cm bearing length)
  • Place lintels with proper orientation and level
  • Verify correct position before continuing masonry
  • Support lintels until mortar achieves strength (min. 3 days)
  • Install sill bricks with proper slope (min. 10° outward)
  • Ensure projection as per drawing (typically 30-50mm)
  • Provide drip course under projecting sill
  • Seal joints thoroughly to prevent water penetration
  • Check squareness of openings (diagonal measurements)
  • Maintain specified tolerance (±5mm)
  • Verify lintel level and alignment
  • Ensure proper flashing where required
8
Curing & Protection
  • Cover top of incomplete walls overnight
  • Protect fresh masonry from rain and direct sunlight
  • Shield walls from strong winds to prevent premature drying
  • Suspend work during adverse weather conditions
  • Begin curing 24 hours after completion
  • Keep masonry work damp for minimum 7 days
  • Apply water using fine spray, avoiding erosion of joints
  • Increase curing period in hot weather conditions
  • Prevent loading of new walls for 14 days
  • No heavy mounting/fixing until mortar achieves full strength
  • Protect corners and edges from impact damage
  • Restrict scaffolding loads on new masonry
  • Check daily for cracks or movement
  • Monitor joint integrity during curing
  • Verify effectiveness of curing methods
  • Document any defects for remedial action

8. Material Testing & Quality Control

Material/Test Test Method Acceptance Criteria Frequency
Brick Compressive Strength IS 3495 Part 1 Min 3.5 N/mm² (common), 7.5 N/mm² (engineering) 5 bricks per 10,000
Brick Water Absorption IS 3495 Part 2 15-20% by weight 5 bricks per 10,000
Mortar Cube Strength IS 2250 Min 7.5 N/mm² at 28 days 6 cubes per day
Sand Gradation IS 2116 Zone II preferred Per batch/source
Cement Quality IS 8112/269 As per grade specification Per delivery
Wall Plumb Check Plumb bob/Level ±10mm in 3m height Every 5m length
Joint Thickness Scale/Gauge 10mm ± 2mm Every course

9. Safety Guidelines

PPE Requirements

Helmets, gloves, safety glasses, dust masks, safety boots for all personnel

Work at Height

Secure scaffolding, guard rails, safety harness for work above 2m height

Manual Handling

Proper lifting techniques, team lifting for loads >25kg, use mechanical aids when possible

Housekeeping

Clean work area, clear access paths, proper waste disposal, organized material storage

Tool Safety

Inspect tools daily, maintain in good condition, store properly when not in use

Hazard Protection

Eye wash stations nearby, cement burn prevention, dust control measures

Training

All workers trained in safe masonry practices and emergency procedures

First Aid

First aid kit readily accessible, trained first aider on site at all times

10. Emergency Preparedness

First Aid Kits

Accessible at all work areas, regularly inspected and restocked

Emergency Contacts

Clearly displayed on site with local emergency services numbers

Wall Collapse Response

Evacuation plan & immediate actions to secure the area and provide medical assistance

Chemical Exposure

Eye wash station and procedures for cement or admixture contact

11. Troubleshooting & Common Issues

Efflorescence (White Deposits)
  • Cause: Soluble salts migrating to surface due to moisture movement
  • Solution: Use low-salt content materials, protect from excess moisture, clean with diluted acid solution (1:10 acid:water) if needed, ensure proper DPC installation
Cracking in Mortar Joints
  • Cause: Excessive shrinkage, foundation movement, poor curing, or inadequate bond
  • Solution: Use correct mortar mix with proper sand gradation, ensure thorough curing, install expansion joints at 6-9m intervals, improve bonding techniques, check foundation stability
Wall Bulging
  • Cause: Excessive loading, inadequate bonding, poor foundation, or lateral pressure
  • Solution: Install wall ties or reinforcement, strengthen foundation, reduce load on wall, ensure proper bonding between courses, check for water accumulation behind wall
Rain Penetration
  • Cause: Poor brick quality, inadequate pointing, absence of DPC, or poor detailing
  • Solution: Apply waterproofing treatment, repoint joints, install flashing/DPC correctly, use water-resistant mortar additives, improve window/door detailing

12. Environmental Considerations

Water Management

Minimize water wastage during curing and cleaning, collect and reuse where possible

Waste Reduction

Reuse broken bricks for filling, proper segregation and disposal of construction waste

Dust Control

Water spraying during cutting operations, dust barriers around work area, covered material storage

Weather Considerations

Avoid extreme temperatures (<5°C or >40°C), protect from rain, adjust curing methods by season

13. Pro Tips

Brick Soaking

Soak bricks just until bubbling stops (usually 2-3 hours) - oversaturated bricks weaken mortar bond

Joint Thickness

Maintain consistent 10mm joints - thicker joints reduce wall strength, thinner joints compromise durability

Corner Construction

Build corners first and fill in between - creates straight, plumb walls with minimal adjustment

Hot Weather Working

Dampen bricks more frequently, add set retarders to mortar, and schedule work during cooler hours

Perfect Alignment

Use gauge rods marked with course heights rather than measuring each course individually

Mortar Application

Apply "butter" to brick ends before placing rather than trying to fill vertical joints after placement

Wall Strength

Include header courses every 6th course in running bond to improve wall strength and stability

Efficient Curing

Use burlap soaked in water and covered with plastic sheets for more effective curing with less water

14. Documentation & Records

15. Acceptance Criteria

Dimensional Tolerance: ±10mm for wall thickness, ±5mm for course height
Verticality: Maximum deviation 10mm in 3m height
Joint Thickness: 10mm ± 2mm for both horizontal and vertical joints
Mortar Strength: Minimum 7.5 N/mm² at 28 days
Surface Finish: Uniform appearance, no visible defects or staining
Bond Pattern: Consistent throughout, proper overlap as specified
Openings: ±5mm for dimensions, square and plumb

16. Conclusion

By following this comprehensive Standard Operating Procedure, brickwork and masonry construction can be executed efficiently, ensuring structural integrity, aesthetic finish, and compliance with IS standards. Proper execution and strict adherence to safety measures will result in durable, high-quality masonry structures. Regular quality checks, material testing, and documentation will help maintain high standards throughout the construction process, resulting in masonry work that combines functionality, durability, and visual appeal while meeting project specifications and ensuring long-term performance.

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