7 Smart Ways To Use Brickforce For Crack-Free Masonry Walls

Cracking is one of the most frustrating issues in masonry construction. Even the most skilled bricklayer can find their work marred by unsightly cracks caused by temperature fluctuations, settlement, shrinkage, or structural movement. Fortunately, modern building practices offer a reliable and cost-effective solution — brickforce.

Brickforce reinforcement, when used correctly, can transform the strength and longevity of brick and block walls. At Vulcania Reinforcing, brickforce is one of the company’s cornerstone products — designed and manufactured locally to meet South Africa’s diverse climate and building needs.

Whether you are constructing a suburban boundary wall or a multi-story commercial façade, understanding how to use BrickForce properly will go a long way in ensuring a crack-free, durable result.

Understanding Brickforce And Its Role In Masonry

Brickforce consists of two parallel high-tensile steel wires joined by cross wires. It is placed horizontally within the mortar joints of masonry walls, effectively acting as a hidden reinforcement layer. As mortar and masonry expand and contract, brickforce helps resist tensile forces, spreading them evenly through the wall and reducing the likelihood of cracking.

In South Africa, where buildings face extreme thermal cycles, expansive clay soils, and frequent moisture variations, the use of brickforce is not merely an option — it is a smart preventive measure. As Vulcania explains, the product’s versatility allows it to strengthen masonry while maintaining aesthetic appeal, since it remains invisible once installed.

International masonry research supports this approach. The National Concrete Masonry Association notes that continuous horizontal reinforcement within bed joints is among the most effective ways to control shrinkage and temperature cracking in masonry structures.

The Science Behind Crack Prevention

To appreciate why Brickforce works so well, it helps to understand the problem it solves. Masonry, while strong in compression, is relatively weak in tension. When temperature changes, moisture loss, or structural loads cause the wall to stretch or move, tiny tensile stresses develop. Without reinforcement, these stresses release abruptly — forming cracks that can propagate and widen over time.

By inserting brickforce in the mortar bed, you introduce tensile strength where it is needed most. When steel wires bond to the mortar, they bridge micro-cracks and hold them tightly closed. Instead of one wide, visible crack, stresses are distributed evenly across the structure, resulting in a stable, longer-lasting wall.

Moreover, high-quality galvanised brickforce, like that offered by Vulcania Reinforcing, resists corrosion even in coastal or humid regions — a crucial consideration for projects in places like Durban or Gqeberha where sea air accelerates steel deterioration.

1. Reinforce Long Wall Spans To Distribute Stresses

The first and most common application is using brickforce in long wall runs, typically placing it in every second or third mortar bed. Long, uninterrupted sections of brickwork are especially vulnerable to shrinkage and temperature cracking. By reinforcing these joints at regular intervals, you allow the wall to flex slightly without forming visible cracks.

When installing Brickforce, ensure it lies flat and is fully embedded in mortar, with a minimum lap of 225 mm at the joins. Any bends or air gaps will weaken its performance.

For large structures or high-load applications, a thicker gauge may be required — and Vulcania’s technical team can recommend the appropriate diameter for your project.

2. Strengthen Stress Points Around Openings And Corners

Cracks often appear around window and door openings where stress concentrations occur. These points, being weaker due to discontinuities, need additional support. Laying brickforce directly above and below openings helps distribute the loads away from vulnerable areas.

Similarly, at wall junctions and corners, continuous brickforce ties the walls together, reducing differential movement. As Bekaert explains, tying corners with reinforcement allows the wall to behave as a single, unified element — reducing the risk of step cracks that run diagonally from openings.

3. Pair With Proper Expansion And Control Joints

While brickforce provides tensile reinforcement, it does not eliminate the need for expansion and control joints. These joints act as deliberate “crack zones” that allow the wall to move without damage. The best results are achieved by combining both approaches: reinforcement between control joints and the use of flexible sealant within them.

According to masonry standards and technical guides, control joints should be placed at regular intervals (typically every 6 m for clay brickwork) and at points of structural change. Brickforce runs continuously between these joints, distributing stress evenly and keeping cracks narrow and controlled.

4. Select The Right Brickforce Type For The Environment

Choosing the correct brickforce material is as important as placement. In inland regions, standard mild steel or black wire brickforce may suffice. However, in coastal or humid areas, galvanised or stainless-steel brickforce is essential to prevent corrosion.

Vulcania’s brickforce range includes multiple options in different widths and gauges, all manufactured to meet SABS quality standards. For typical 110 mm bricks, 75–100 mm wide brickforce is used. For concrete blockwork, wider strips may be necessary to ensure full coverage across the bed joint.

A small investment in the right specification prevents costly repairs later. Once corrosion sets in, it not only weakens the wall but can also cause “rust jacking,” where expanding rust physically cracks the masonry.

5. Embed Brickforce Correctly – Workmanship Matters

Brickforce only performs if properly installed. Poor embedding — where the reinforcement sits on top of the mortar rather than within it — severely reduces its bond strength. Always place brickforce into a full, even mortar bed, ensuring it’s surrounded by mortar both above and below.

It should also be kept clean and free from mud or mortar droppings before use. Overlaps must be consistent and secured, maintaining continuous strength through the wall length. The Masonry Workshop notes that consistent embedment is one of the most important factors influencing the effectiveness of brickforce.

On larger projects, supervisors should routinely inspect that brickforce is installed to specification — ensuring joints are level, overlaps are sufficient, and corrosion protection is intact.

6. Combine Brickforce With Structural Reinforcement

For maximum durability, integrate brickforce with other structural reinforcement systems. For example, above door or window openings, tie the brickforce into lintels to strengthen load distribution. At floor or roof levels, it can work in tandem with reinforced concrete ring beams to tie the building together laterally.

In high-stress walls, especially load-bearing ones, consider combining brickforce with reinforcement or welded mesh for additional tensile capacity. As Bekaert’s research highlights, multi-layer reinforcement systems help maintain crack widths below serviceability limits, even in highly stressed masonry.

This holistic approach ensures that all elements — from foundation to parapet — move together rather than independently, minimising tension points and cracks.

7. Maintain, Inspect, And Protect Masonry Over Time

Even with perfect design and installation, time and weather can still impact masonry. Regular maintenance ensures small cracks do not escalate. Inspect your walls annually for signs of movement, especially after heavy rainfall or drought, as clay-based soils can swell and contract significantly.

Should minor cracks appear, repair them early using flexible mortar or specialised crack fillers. In extreme cases, where cracks indicate foundation movement, seek professional assessment from a structural engineer. Preventative maintenance — cleaning gutters, ensuring proper drainage, and avoiding water pooling — all contribute to the long-term health of the wall.

For property developers, partnering with a trusted supplier like Vulcania Reinforcing Solutions ensures consistent product quality and expert guidance throughout the construction process.

We Provide Quality, Expertise, And Local Reliability

Based in South Africa, Vulcania Reinforcing has built its reputation on delivering high-quality steel reinforcement products — from rebar and mesh to brickforce. What sets Vulcania apart is not only the strength of its materials but its understanding of local construction challenges.

Their brickforce products are manufactured to rigorous standards, ensuring even wire spacing, reliable welds, and accurate dimensions. This attention to detail means builders can rely on consistent performance across every roll, which is an essential factor when precision and safety are on the line.

Moreover, Vulcania offers custom-cut and bent reinforcement solutions, allowing contractors to reduce waste and installation time. This level of flexibility, paired with reliable delivery and technical support, positions the company as one of the top reinforcement suppliers in South Africa.

Building Smarter, Stronger, And Longer-Lasting Walls

Using brickforce effectively is not simply about following a checklist — it is about understanding how masonry behaves and reinforcing it intelligently. Each wall tells its own story, shaped by its materials, location, and purpose. By applying the principles discussed — reinforcing long runs, protecting stress zones, combining with control joints, and ensuring proper installation — you can significantly improve structural integrity.

Brickforce may be invisible once the wall is plastered, but its impact is lasting. It embodies the principle that real strength often lies beneath the surface, a quiet assurance that the structure will stand firm for decades to come.

For architects, engineers, and contractors seeking durable, crack-resistant masonry, Vulcania Reinforcing’s Brick Force is the trusted choice — a product that merges traditional craftsmanship with modern engineering insight.

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