Masonry & Brickwork
QA inspection checklist

Materials

1. 1.

   Brick/block type and colour match approved samples
   What to look forBricks compared on site against the approved benchmark panel — colour, texture, frog/perforation pattern. Strength class marked on packaging. Multiple deliveries blended to avoid banding (typically from 3+ packs simultaneously).
   Acceptable whenBricks to BS EN 771-1 (clay), BS EN 771-2 (calcium silicate), or BS EN 771-3 (concrete). Compressive strength typically Class 1 (10 N/mm²) for facing, Class 2 (15+ N/mm²) for engineering. Colour match to approved panel within typical weathered tolerance.
   StandardBS EN 771-1 to 6:2011+A1:2015 — Specification for masonry units. NHBC Standards Chapter 6.1. BS 5628 (now superseded by Eurocode 6).
   Common defectsBanding (colour stripes) where one pack used at a time without blendingWrong frog orientation — frog down on solid bricks (frog must be up to fill)Engineering brick used in facing position — visual mismatchCalcium silicate used externally where freeze-thaw resistance not specifiedCracked or chipped bricks installed — typical at quoins
2. 2.

   Mortar mix to specification
   What to look forMortar mixed in correct proportions — site mix or factory-batched silo. Workable for 2-4 hours after mixing (cement); not retempered with water once stiffened. Plasticiser used not washing-up liquid. Sand free of contamination.
   Acceptable whenDesignation per BS EN 998-2 / NHBC: M12 (1:0.25:3) for engineering, M6 (1:0.5:4-4.5) for general use external, M4 (1:1:5-6) for general internal, M2 (1:2:8-9) for soft facings. Use within 2 hours of mixing for cement mortars.
   StandardBS EN 998-2:2016 — Masonry mortars. BS EN 1996-2 (Eurocode 6 Part 2). NHBC Standards Chapter 6.1.
   Common defectsMortar too strong — M12 used with soft facing brick, mortar harder than brick = brick spalling under movementMortar too weak — falls out under freeze-thawRetempered mortar — mixed in morning, used in afternoon, weak bondWrong sand grading — too fine = high water demand, weak mortarPlasticiser overdosed — air content > 20%, frost vulnerable
3. 3.

   DPC/DPM material matches specification
   What to look forDPC type matches drawing — typically polyethylene, pitch polymer, or hessian/asphalt. Width covers full thickness of wall. Manufacturer's identification visible on roll. Lap minimum 100 mm at joints.
   Acceptable whenDPC to BS 6398 or BS 8215. Minimum width matches wall thickness. Minimum 100 mm lap at joints, sealed/welded. Position 150 mm minimum above external ground level (NHBC). Continuous and unbroken.
   StandardBS 6398:1983 — Bitumen DPCs. BS 8215:1991 — Code of practice for DPC design and installation. NHBC Standards Chapter 6.1.
   Common defectsDPC narrower than wall — water bridges over edgeLap < 100 mm or unsealed — capillary pathDPC < 150 mm above ground — splash penetrationDPC torn during bricklaying — punctured by snots/aggregateWrong type — pitch polymer used where polyethylene specified
4. 4.

   Wall ties correct type and spacing
   What to look forWall ties match the design — type 1 (heavy duty), type 2, type 3, or type 4 (light duty) per BS EN 845-1. Stainless steel for cavity walls in coastal/exposed locations. Tie length appropriate for cavity width. Drip in centre.
   Acceptable whenSpacing per Eurocode 6 / PD 6697: 900 mm horizontally × 450 mm vertically (max 2.5 ties/m²) for general use. 300 mm vertically at jambs, openings, and movement joints. Embedment ≥ 50 mm each leaf. Drip pointing down.
   StandardBS EN 845-1:2013+A1:2016 — Wall ties. PD 6697:2019 — Recommendations for design of masonry. NHBC Standards Chapter 6.1.
   Common defectsTies sloping inward (toward inner leaf) — water runs into buildingDrip not in cavity — water tracks across to inner leafTie spacing exceeds 2.5/m² — wall instabilityInsufficient ties at openings — typically only 300 mm vertical missedMild steel used in cavity walls — corrodes within 10-15 years

Setting Out & Laying

1. 5.

   Setting out checked against drawings
   What to look forFirst course laid dry to confirm coursing — bond pattern matches drawing. Quoins set with profile boards. Window/door positions checked off datum. Diagonal measurements confirm corners are square.
   Acceptable whenSetting out to ±10 mm of theoretical line. Bond pattern (stretcher / Flemish / English) matches design. Coursing tally with brick gauge so no cuts < 75 mm in face brickwork.
   StandardBS EN 1996-2:2006 (Eurocode 6 Part 2) cl.2.1. PD 6697:2019. NHBC Standards 6.1.
   Common defectsWall position out by 25+ mm — dimension confused on drawingBond pattern broken at openings — half-bricks visible at jambsCoursing not gauged — small cuts at lintels or eavesOut-of-square corners — diagonals differ by > 15 mm
2. 6.

   Courses level and plumb

   Record: Deviation (mm)
   What to look forCourses level along wall length — string line from end to end. Wall plumb checked with spirit level on quoins and at intervals along face. No rippled or stepped vertical faces.
   Acceptable whenVerticality ±8 mm in storey height (3 m), ±20 mm overall building height per PD 6697. Course level deviation ±8 mm in 5 m, ±15 mm in any direction overall. Bow ±5 mm in 5 m straight edge.
   StandardPD 6697:2019 cl.7.6 — Tolerances. NHBC Standards 6.1. BS 5606:1990.
   Common defectsWall leans outward at top — bricklayer not checking plumb at each liftCourse rises and falls — not gauging at quoins consistentlyBow in long straight wall — no intermediate plumb checksQuoin out of plumb — corner profile not used
3. 7.

   Bed and perp joints consistent

   Record: Joint width (mm)
   What to look forBed and perp joints consistent width — typically 10 mm. Perps line up vertically (or alternate) per bond pattern. Joints fully filled — no slumped or hollow perps. Mortar pressed flush to brick face.
   Acceptable whenJoint width 10 mm nominal, ±3 mm per PD 6697. All joints fully filled — no voids ("snots and bridges" only). Perp joints staggered per bond. Joint variation visible on face brickwork should be minimal.
   StandardPD 6697:2019. NHBC Standards 6.1. BS EN 1996-1-1 cl.8.
   Common defectsHollow perps — bricklayer "buttering" only the front of the brickVariable joint width 7-15 mm — visible on facing brickworkStepped perps — bond pattern brokenJoints not pressed flush — mortar setting back from face
4. 8.

   Cavity width maintained and clean

   Record: Cavity (mm)
   What to look forCavity width matches drawing throughout the wall — no narrowing at openings. Cavity free of mortar droppings — battens/boards used to catch droppings. No bridging at lintels, sills, or ties.
   Acceptable whenCavity width per design, typically 50-100 mm clear plus insulation. Tolerance ±10 mm. Cavity must remain clear — no mortar bridging on ties or against insulation. NHBC require minimum 50 mm residual cavity for fully filled, or clear cavity for partial fill.
   StandardPD 6697:2019 cl.10. NHBC Standards Chapter 6.1. BS 8104 — Code of practice for assessing exposure of walls to wind-driven rain.
   Common defectsMortar dropping bridge at base — water tracks across to inner leafSnots on ties — "bridges" for moistureCavity narrowed at openings — no clearance for cavity trayInsulation pushed against outer leaf with no residual cavityCavity wider than design — ties too short for embedment
5. 9.

   Wall ties installed at correct centres
   What to look forTies at design centres horizontally and vertically. Additional ties at jambs of openings (within 300 mm and at 300 mm vertical spacing). Tie level horizontal — drip pointing down. Bedded minimum 50 mm into each leaf.
   Acceptable whenPD 6697 / NHBC: 2.5 ties/m² minimum (typically 900 × 450 mm grid). At openings, jambs and reveals: 300 mm vertical centres, within 300 mm of opening. Embedment ≥ 50 mm in each leaf. Tie level or pitch outward.
   StandardPD 6697:2019 cl.10. BS EN 1996-1-1. NHBC Standards 6.1.
   Common defectsTies missed at jambs — opening cracks at cornersTies slope inward — drip useless, water entersDrip on the outer end (against external leaf) instead of central — water tracks into cavityInsufficient ties around openingsEmbedment too shallow — tie pulls out under wind suction
6. 10.

   Insulation fitted tightly
   What to look forCavity insulation pushed tight against the inner leaf with no gaps at edges or joints. Boards staggered. Held in place with retaining clips at minimum 5 per board. No mortar contamination on board face.
   Acceptable whenInsulation type, lambda value, and thickness per spec. Boards butt-tight, all gaps < 5 mm sealed or stuffed. Retaining clips per manufacturer's spec, typically 4-6 per 1200×450 board. Continuous from base DPC to wall plate.
   StandardBS EN 13162-13167 — Thermal insulation products. NHBC Standards 6.1. PD 6697 cl.10.
   Common defectsGaps at board edges — cold bridges, condensation riskBoards not staggered — vertical thermal bridgeInsulation crushed/wedged — lambda value compromisedMortar droppings on board face — locally reduces performanceMissing retaining clips — boards slip during construction

Details & Finishing

1. 11.

   Lintels installed to correct bearing
   What to look forBearing length matches the lintel manufacturer's data — typically 150 mm minimum each end. Lintel sat on full bed of mortar. Cavity tray over lintel (combined with the lintel or separate). Stop ends to cavity tray. Weep holes 450 mm centres.
   Acceptable whenMinimum bearing 150 mm each end (NHBC). Steel lintel: cavity tray and DPC over lintel, with stop ends. Concrete lintel: separate cavity tray with stop ends. Weep holes at 450 mm max centres above lintel.
   StandardBS EN 845-2:2013 — Lintels. NHBC Standards Chapter 6.4. PD 6697:2019.
   Common defectsBearing < 150 mm — risk of crushing or rotationNo cavity tray — water pools on lintel and tracks insideCavity tray without stop ends — water flows out at jambsNo weep holes — water trapped above lintelLintel bedded on dry brick — uneven load distribution
2. 12.

   Movement joints at correct centres
   What to look forMovement joints continuous from foundation/DPC to top of wall. Joint depth matches wall thickness. Joint filler (closed-cell) installed before sealant. Bond breaker at base of sealant. Slip ties span the joint where structural.
   Acceptable whenSpacing per PD 6697: clay brickwork ~12 m max, calcium silicate ~7.5 m, concrete blockwork ~6 m. Joint width typically 10-20 mm. Sealant depth ½ × width. Located at junctions, openings, and changes in wall height.
   StandardPD 6697:2019 cl.6 — Movement and accommodation. NHBC Standards 6.1. BS EN 1996-2.
   Common defectsMovement joint not continuous — runs only part way up wallSpacing exceeds maximum — long walls develop random crackingJoint filled with mortar — defeats purposeNo slip ties at joints — wall destabilisedSealant adheres to backer rod (no bond breaker) — splits when wall moves
3. 13.

   DPC correctly lapped and dressed
   What to look forDPC continuous, sealed at all laps. Dressed up at jambs and over lintels. Stepped at split-level DPCs with overlap. Tucked into mortar bed both sides of cavity. No bedding on DPC bridging cavity.
   Acceptable whenLap minimum 100 mm, sealed (welded for polyethylene, bonded for pitch polymer). DPC at minimum 150 mm above external ground. Continuous around perimeter. Cavity trays stepped 150 mm minimum at each level.
   StandardBS 8215:1991. NHBC Standards 6.1 and 6.4. PD 6697:2019.
   Common defectsDPC lap unsealed — capillary moisture pathDPC bridged by mortar dropping in cavityCavity tray stepped less than 150 mmDPC torn during construction — punctured by aggregateNo DPC over lintel — water from wall above tracks in
4. 14.

   Pointing finish consistent and clean
   What to look forPointing profile matches spec — bucket-handle, weather struck, recessed, or flush. Joints raked to correct depth and tooled when "thumb-press" hard. No smearing or staining of brick face. Consistent visual appearance.
   Acceptable whenProfile per spec; bucket-handle most common externally. Tooling depth typically 5-10 mm. Joints fully filled, no holiday. Brick face cleaned of mortar daub before set. PD 6697 recommends weather-struck or bucket-handle for exposed conditions.
   StandardPD 6697:2019. NHBC Standards 6.1. BS 5390 (Stone masonry).
   Common defectsMortar smearing on brick face ("snots") — etched on after setProfile inconsistent — flush in one area, recessed in nextJoints not tooled until too hard — surface rakes off, soft mortar exposedRecessed pointing in exposed location — water pools on bedDifferent mortar batch colour — visible banding
5. 15.

   Weep holes installed and clear
   What to look forWeep holes at all DPCs and cavity trays. Open and clear — not full of mortar. Spacing matches design. Weep vents (formed weeps) preferred — block out vermin while allowing drainage. Located at low point of cavity tray.
   Acceptable whenMaximum 450 mm centres above DPCs/cavity trays per NHBC. Minimum 2 weeps per opening. Weep vents to BS EN 845-1. Position within 50 mm of cavity tray low point.
   StandardNHBC Standards 6.1 and 6.4. PD 6697:2019. BS EN 845-1.
   Common defectsWeep holes blocked with mortar — water trapped, eventually backs upSpacing > 450 mm — drainage inadequateNo weep vents — vermin and insect ingressWeep located too high above tray — water pools belowOpen perpend used as weep without retainer — fills with debris

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