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Brick Sizes and Coursing

Brick dimensions are specified in nominal and actual sizes. Nominal size includes the thickness of a standard mortar joint, while actual size is the manufactured brick dimension. A modular brick has a nominal size of 8×4 inches but an actual size of 7-5/8×3-5/8 inches. The difference accounts for a 3/8-inch mortar joint on the top and end.

This modular sizing makes layout predictable. Three courses of modular brick reach exactly 8 inches in height. Five bricks laid end-to-end span 40 inches. Designers use this 4-inch vertical and 8-inch horizontal grid to coordinate window and door openings with brick coursing, reducing cutting and waste.

Non-modular bricks require more careful planning. Utility bricks, engineer bricks, and Norman bricks have different aspect ratios and don't course evenly with modular dimensions. Always verify the actual brick size before ordering, and mock up a small section to confirm joint spacing and coursing before committing to a large order.

Estimating Waste and Breakage

Even experienced masons break bricks. Transportation, handling, cutting, and frost damage all contribute to waste. A general rule is to order 10% extra for simple walls with few openings and 15-20% extra for complex patterns, arches, or curved work.

Cutting creates additional waste. Every cut brick generates at least one unusable piece. Soldier courses, rowlock caps, and angled cuts can push waste above 20%. If you're learning, budget extra—your first few courses will likely include mistakes, broken bricks, and discarded units.

Save leftover bricks for future repairs. Brick color and texture vary between production runs, and discontinued styles are nearly impossible to match years later. A stash of original bricks ensures seamless repairs when a mailbox anchor pulls out or a freeze crack needs patching.

Brick Types and Applications

Face brick is what you see. It's fired to uniform color, has tight tolerances, and comes in a huge range of textures and hues. Use face brick for any visible surface where aesthetics matter. It costs more but delivers the curb appeal that justifies the investment.

Common brick is the workhorse. It's less consistent in color and texture, making it unsuitable for exposed work, but it's structurally identical to face brick and costs significantly less. Use common brick for backing wythes, foundations, and structural cores hidden behind veneer.

Firebrick withstands high temperatures without cracking or spalling. It's essential for fireplace fireboxes, wood stove surrounds, and chimney flue linings. Never substitute standard brick in high-heat applications; it will crack and fail, creating fire and carbon monoxide hazards. Paving brick is denser and harder than wall brick, designed to handle vehicular loads and abrasion. Use it for driveways, patios, and walkways where standard brick would crack under traffic.