Masonry Restoration: Why Walls Fail and How We Fix ThemWords: Aric Hutchinson, Architectural Representative Masonry doesn’t crack. Old brick never has issues. Every masonry wall lasts 100 years or more… right? If only that were true. Masonry is one of the most durable building materials ever used, but like all construction, it responds to time, movement, moisture, and design limitations. Cracking, veneer separation, corrosion, flashing failures, and structural distress are common conditions encountered in older buildings. Most of these issues are not the result of poor workmanship; they are the result of movement and misunderstood behavior. Why Masonry Fails Over TimeCommon causes of masonry distress include differential movement between veneer and backup, thermal expansion and contraction, moisture intrusion and freeze–thaw cycling, corrosion of embedded steel or relief angles, settlement, and long-term structural creep. Many older masonry buildings were constructed with limited or no positive mechanical connection between wythes or between veneer and backup. Gravity and friction were often relied upon to hold the wall together. Over the decades, those assumptions fail, and masonry begins to crack, bulge, or separate. Modern Restoration SolutionsToday’s masonry restoration relies on engineered anchoring and reinforcement systems that allow walls to be stabilized and reconnected with minimal disruption. Among the most widely accepted solutions are stainless steel helical anchoring and reinforcement systems. These systems are designed to: Re-anchor displaced or delaminated masonry Stabilize bulging walls Reinforce cracked masonry Restore load transfer to the structural backupJust as importantly, they can be installed discreetly through mortar joints and concealed after repair, an essential benefit for historic and architecturally sensitive buildings.How Helical Anchors Work Helical anchors are mechanical fasteners fabricated from stainless steel. Their continuous helical profile allows them to cut their own path into mortar, brick, CMU, or concrete, creating a threaded mechanical bond without expansion forces or adhesives. When installed, the anchor transfers lateral loads from the masonry veneer back into the structural backup while accommodating minor differential movement. This makes them well-suited for restoration applications where existing materials and conditions vary. Installation Overview While each project must be engineered for its specific conditions, the general installation process is consistent: 1. A pilot hole is drilled through the mortar joint of the veneer. 2. The hole continues through the cavity and into the backup material. 3. The helical tie is driven using a manufacturer-approved installation tool. 4. The tie is embedded to the required depth. 5. The mortar joint is patched to match the surrounding masonry. Because installation occurs at the mortar joint, disturbance to masonry units is minimized. Common Backup Conditions In multi-wythe and three-width brick walls, helical ties are used to reconnect exterior wythes to structural wythes, restoring composite behavior and stabilizing bulging masonry. When the backup is reinforced concrete or grouted CMU, helical ties embed directly into the backup, providing reliable load transfer without inducing expansion stresses. Field testing is recommended where substrate quality varies. For metal stud backup, helical ties may be used selectively in restoration scenarios to reconnect displaced veneer, provided stud engagement, corrosion resistance, deflection allowance, and load capacity. Crack Stitching with Helical Reinforcement Cracked masonry can be reinforced using helical reinforcement bars installed within horizontal mortar joints. This technique redistributes tensile forces across the crack, restores continuity, and helps prevent further propagation, all while remaining visually discreet.Helical Anchors in Repair and Construction The versatility of helical anchors makes them particularly effective for addressing structural deficiencies that develop in brick and masonry systems over time and in new buildings. Common applications include- reinforcing deteriorated steel lintels, correcting failed brick relief points, and stabilizing masonry affected by long-term moisture exposure.Many masonry distress conditions, such as cracking, displacement, and efflorescence, are often symptoms of underlying issues, including inadequate cavity drainage and air flow, compromised through-wall flashing, or differential movement between structural components. While moisture management deficiencies must be corrected at the source, helical anchoring systems can be incorporated as part of a comprehensive repair approach to restore stability and limit further damage. During repair operations, helical pins can be strategically installed to temporarily support masonry walls above the work area. This controlled load transfer helps maintain wall alignment and structural integrity while repairs are performed, reducing the risk of unintended movement or progressive damage. In addition, helical anchors can be installed to provide permanent reinforcement, ensuring proper anchor spacing and added structural stability. When designed and installed, helical anchoring systems allow contractors and building owners to proactively address structural weaknesses before the cumulative effects of gravity loads, environmental exposure, and time lead to more extensive deterioration. As a result, these systems offer a practical, minimally invasive solution for extending the service life of masonry assemblies while preserving safety, performance, and constructability. Best Practices and Code Considerations In accordance with MCAA guidelines and TMS 402/602, masonry restoration systems must provide verified load transfer, adequate embedment, corrosion resistance, and accommodation for movement. Field verification and on-site pull-out testing should be performed to confirm that installed helical anchors are achieving the required load capacity in actual field conditions. Testing should be completed and documented by an independent, qualified third-party agency to provide objective verification of performance. These procedures help confirm correct installation, validate design assumptions, and provide confidence that the anchors will perform reliably for the life of the structure. Closing Thoughts Masonry restoration is not about making buildings new; it is about making them whole again. Walls move, brick cracks, and details fail. With modern helical anchoring and reinforcement systems, masonry professionals can stabilize existing construction and extend the life of buildings for decades to come. That’s not just good construction, it’s good stewardship.About: MAP Partner
