Brickwork & Masonry SOP | Civil With Karthik

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.

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. Responsibilities

Site Engineer

Oversees overall process & ensures compliance

Mason Supervisor

Leads masonry team & ensures quality

Safety Officer

Ensures safety protocols are followed

Masons & Helpers

Execute masonry work & material handling

Quality Inspector

Conducts material and workmanship quality checks

Material Manager

Ensures timely availability of quality materials

4. Materials & Equipment

Bricks/Blocks

Clay bricks, AAC blocks as per specifications

Mortar

Cement, sand, water (1:4/1:6 ratio)

Tools

Trowel, plumb bob, level, line thread

Mixing Equipment

Mixers, pans, buckets

Scaffolding

Secure platforms for height work

Additives

Waterproofing or other admixtures

Water

Clean potable water free from impurities

Testing Equipment

Compression testing machine, water absorption test kit

5. 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

6. 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

7. 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

8. Quality Control & Testing

Material Testing

Brick compressive strength, water absorption, and dimensional tolerance tests

Mortar Testing

Cube strength tests (min. 7.5 N/mm²), consistency checks, mix ratio verification

Verticality Checks

Maximum deviation 10mm in 3m height; check every 2m length of wall

Horizontal Alignment

Maximum deviation 5mm in 5m length; verify at each course level

Joint Verification

10mm ± 2mm thickness for both horizontal and vertical joints

Dimensional Accuracy

Wall thickness tolerance ±5mm; opening dimensions ±10mm

Visual Inspection

Check for cracks, chips, efflorescence, and surface defects

Bond Pattern

Verify correct pattern implementation and consistent appearance

9. Documentation

Material inspection reports including test certificates for bricks and cement
Daily work progress reports with quantities completed and location details
Quality control checklists for each wall section and stage of work
Test results for materials including mortar cube tests and brick strength
Photographic documentation of key stages and completed work
Inspection signoff forms from site engineer and quality controller
Non-conformance reports and corrective actions taken

10. References & Standards

IS 2212:1991 - Code of Practice for Brickwork
IS 2250:1981 - Code of Practice for Preparation and Use of Masonry Mortars
IS 1077:1992 - Common Burnt Clay Building Bricks - Specification
IS 2185:2005 - Concrete Masonry Units Specification
IS 3495 (Parts 1-4):1992 - Methods of Tests of Burnt Clay Building Bricks
IS 2116:1980 - Specification for Sand for Masonry Mortars
IS 383:2016 - Specification for Coarse and Fine Aggregates
Project-specific specifications and drawings

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. Conclusion

By following this 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 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.