What is brick spalling and what causes it?

Brick spalling occurs when the surface of brick masonry begins to chip, flake, or break away. In commercial, municipal and institutional buildings throughout Massachusetts and New England, spalling is a common issue due to the area’s challenging weather patterns and environmental exposures.

The primary cause of brick spalling is moisture penetration. When water enters brickwork through cracks, open mortar joints, or damaged sealants, it can become trapped inside the brick or mortar. In New England, where winter freeze-thaw cycles are frequent, this trapped moisture expands as it freezes, causing pieces of the brick to break off, flake, crack, or signs of white efflorescence over time.

Other contributing factors include the use of de-icing salts on adjacent surfaces, improper repairs with incompatible materials, or even deterioration from routine age and exposure. For many older or historic structures, original construction materials may be less resistant to modern environmental stressors, increasing the risk of spalling over decades.

Spalling not only affects appearance but can also reduce the weather resistance of the wall, lead to further deterioration, and eventually compromise the structural integrity of masonry assemblies. In commercial settings, this can increase the risk of water intrusion, energy loss, and more costly repairs if not addressed proactively.

Preventing and addressing brick spalling requires a combination of regular inspection, sound maintenance planning, and the use of proper repair materials. Professional evaluation should include review of site drainage, flashing systems, sealant joints, and the condition of mortar and brick surfaces. Early identification allows for targeted repairs such as tuckpointing, repointing, or replacing damaged bricks with materials suited for New England climates.

For property managers, facility operators, engineers, and municipalities, prioritizing masonry inspections and preventative maintenance is essential for long-term building performance, safety, and asset value.