The Problem
The west-facing wall of a detached garage had 30 bricks with moderate to severe spalling. The damage pattern told the story - the worst spalling was concentrated in the bottom four courses, exactly where road salt spray and snowmelt splash back hit the wall during winter.
Road salt (sodium chloride and calcium chloride) is extremely aggressive on brick. It creates salt crystallization pressure inside the brick pores - a mechanism similar to freeze-thaw damage but occurring at temperatures well above freezing. The salt crystals grow as the brick dries, exerting pressure that pops the brick face off from the inside.
Our Solution
We sourced matching brick from a salvage yard specializing in 1960s-era Chicagoland residential brick. The original bricks were a standard modular size in a medium red tone - common for the era but no longer manufactured in the exact color. The salvaged brick had weathered to a nearly identical tone.
Each damaged brick was cut out individually using an oscillating multi-tool to avoid disturbing the surrounding brick. New brick was set in Type N mortar matched to the existing joint color. We repointed all joints in a 3-foot radius around each replacement to ensure a consistent appearance and seal.
After completion, we applied a breathable silane-based water repellent to the bottom four courses of the wall. This treatment reduces water absorption by approximately 95% while still allowing moisture vapor to escape - critical for preventing future salt damage without trapping moisture inside the wall.
The Result
The replacement bricks blend seamlessly with the original wall. The water repellent treatment will significantly reduce salt damage going forward, though it needs to be reapplied every 5-7 years to maintain effectiveness.
We recommended the homeowner redirect the downspout on the west side to reduce splash-back and consider a gravel strip along the wall base to minimize salt contact.