Between you and me, matching new brick to old brick is one of those deceptively tricky tasks that can make or break the look of your renovation. As someone who's spent 15 years working with brick—both ancient Roman walls and modern sustainable builds—I can tell you it’s an art and a science. For DIY home builders and renovators who care about the environment but need to keep an eye on the budget, this is a balancing act worth mastering.
You’ve probably heard the buzzwords— embodied energy, U-value, thermal mass—and maybe felt overwhelmed. And maybe you’re skeptical about claims that brick is the greener, better alternative to timber or concrete. I get it. So let’s cut through the jargon and marketing fluff with real talk, practical tips, and some solid numbers.
Why Matching Brick Matters (More Than You Think)
Matching new brick to old brick is about more than just aesthetics. Sure, you want your addition or repair to blend seamlessly with the existing structure. But matching bricks also preserves the building’s thermal performance, structural integrity, and long-term durability.
Imagine you’re adding a new wing to a 1920s brick home. The old bricks have absorbed decades of weather, sunlight, and pollution, subtly changing their color and texture. Using a bright, shiny new brick can stick out like a sore thumb, breaking the visual harmony and potentially lowering the home’s value.
On the other hand, if you try to use cheap, generic bricks just because they’re cheaper or more readily available, you risk mismatches in size, mortar compatibility, and even thermal behavior. That can lead to cracking, water infiltration, or faster deterioration over time. And that’s bad news for your wallet and the planet.
Brick vs. Timber vs. Concrete: What About the Green Factor?
Before diving into brick matching, let's quickly touch on why brick remains a strong contender for eco-conscious renovators.
- Embodied Energy: Embodied energy is the total energy used to extract, manufacture, transport, and install a building material. Bricks, especially handmade or locally produced ones, have moderate embodied energy—typically lower than concrete but higher than timber. However, their incredible longevity (often 100+ years) means the energy cost gets spread out over a long life. Thermal Mass: Bricks act like a thermal battery, absorbing heat during the day and releasing it slowly at night. This can reduce heating and cooling loads, something timber just can’t do. Durability: Bricks resist pests, rot, and fire better than timber. Compared to concrete, bricks tend to have fewer chemical additives and can be more breathable, reducing moisture issues.
Costs vary, but bricks typically range from about $0.50 to $2.50 per brick, depending on size, quality, and source. Timber and concrete prices fluctuate similarly, but the key is in the lifecycle cost and environmental impact, not just the upfront price.
Understanding the Basics of Brick Matching
Here’s the good news: matching new brick to old brick isn’t rocket science, but it requires patience and a bit of detective work. Here’s what to focus on:
Color & Texture: Old bricks usually have muted, weathered tones. Look for bricks that can be custom stained or that naturally match the patina of your existing wall. Size & Shape: Brick dimensions and shapes have changed over the decades. Using bricks with mismatched sizes can create uneven mortar joints and visual disruption. Mortar Color & Composition: The mortar is the unsung hero here. Older mortar tends to be softer and more lime-rich compared to modern cement-heavy mixes. Surface Finish: Is the old brick smooth, sand-faced, or textured? Matching surface finish helps the new bricks blend in visually and functionally.
Step-by-Step Guide to Matching New Brick to Old Brick
Let’s break down the process into manageable steps:
Collect Samples: Take a small brick sample or a clear photo of your existing brick. If you can carefully remove a damaged brick (without causing more harm!), that’s even better. Consult a Brick Matching Service: Companies like Glen-Gery and Belden Brick Company specialize in custom brick for additions. They can analyze your sample and recommend the closest match or even produce custom blends. Order Test Bricks: Before committing, order a small batch of test bricks to see how they weather in your environment and how they look next to your old wall under different lighting. Match Mortar: Have your mason test mortar mixes to find one that matches the color and hardness of the old mortar. Sometimes adding pigments or using lime-based mixes helps. Mock-Up: Build a small mock-up wall section to evaluate the blend. This helps identify any surprises before full-scale work begins.Custom Brick for Additions: What to Expect
Custom brick production isn’t just for museums or high-end commercial projects anymore. Glen-Gery and Belden both offer tailored options including:
- Color Matching: Using natural clays and firing techniques to replicate hues from soft tans to deep reds and browns. Texture Replication: Surface treatments that mimic hand-molded or sand-faced finishes. Size Customization: Adjusting brick dimensions for historical accuracy or architectural harmony.
Prices for custom bricks typically fall in the higher end of the $0.50 to $2.50 range per brick, but consider the value you gain in longevity, curb appeal, and reduced maintenance.
Common Pitfalls and How to Avoid Them
- Using Generic Bricks: These rarely match in color or size and can cause visible seams or stress points in your wall. Ignoring Mortar Compatibility: Hard modern mortars can cause old bricks to crack. Always test mortar mixes before full application. Overlooking Weathering: Remember that new bricks will look different initially but will weather over time. If you want an instant match, custom staining or sandblasting may be needed. Skipping Mock-Ups: Never skip the mock-up phase. What looks good on paper might not translate in natural light or with your specific brick batch.
Real-World Example: A 1930s Tudor Revival Addition
Let me share a quick story from a project I worked on recently. A client wanted to add a sunroom to their 1930s Tudor Revival home. The original bricks were a mix of soft reds and browns with a rough sand-faced texture. Our challenges:
- The original bricks were no longer made. The mortar was a soft lime mix, now hardened and crumbly.
We sent samples to Glen-Gery’s brick matching service. They produced a custom batch with the right color and texture, closely mimicking the patina by adding light sandblasting and re-thinkingthefuture firing adjustments. Meanwhile, our mason mixed a lime-rich mortar tinted with natural pigments to match the softened mortar color.
After a small mock-up and some tweaks, the addition blended so well that even neighbors didn’t notice it was new construction. The client was thrilled, and we stayed within budget by ordering just enough custom bricks without overstocking.
Final Thoughts: Is Brick the Right Choice for You?
Brick is a proven, durable material with environmental benefits when chosen wisely. If you’re renovating an older home, especially one with historic or character-filled brickwork, investing time and a bit of money into matching new brick to old brick pays off in aesthetics, performance, and longevity.
Remember, it’s not about chasing the cheapest option. It’s about smart choices that respect your home’s history and the environment. Using a reputable brick matching service like Glen-Gery or Belden Brick Company can take much of the guesswork out of the process.
So, next time you’re staring at a brick wall wondering how to blend the old and the new without breaking the bank or the planet, think like a Roman builder: use quality materials, test thoroughly, and respect the craftsmanship of the past. And maybe carry a worn-out brick in your pocket for inspiration—trust me, it helps.