Cracking in brickwork doesn't have to mean rebuilding the wall. We diagnose the cause, then stitch the masonry back together with helical stainless reinforcement bedded into the joints.
Understanding brick cracks
Not every crack is structural, but the ones that are usually follow a recognisable pattern. The direction, location, and width of a crack tells you what’s moving and why. Repairing the symptom without fixing the cause is a guaranteed callback.
What is Helibar stitching?
A Helibar (helical bar) is a thin twisted stainless steel rod, typically 6 to 8mm, bonded into a slot cut into the mortar joint. The bar acts as reinforcement across the crack, transferring load and preventing further movement. Multiple bars are installed at staggered courses to tie the wall together horizontally.
The technique is non-invasive: nothing is demolished. After the bars are bedded in a high-strength grout and the joint is repointed to match, the repair is invisible from outside. It’s suitable for heritage walls, exposed brick, and rendered facades.
Our diagnosis process
Crack mapping
We document every crack with photos, measurements, and a sketch of the affected elevation. Width is measured at multiple points along each crack.
Cause identification
We check for failed wall ties, missing lintels, blocked weeps, recent ground works, water leaks, or root encroachment, whatever is actually driving the movement.
Movement monitoring (if needed)
For active cracks we install Avongard tell-tales or fix gauges and monitor over four to twelve weeks to confirm whether movement is ongoing or now dormant.
Repair specification
Helibar count, course spacing, embedment length, and grout type specified in writing, suitable for engineer review or insurance sign-off.
When stitching is the right solution
Helibar stitching works best on dormant cracking caused by historical movement that has now stabilised, for example a settlement event many years ago, or a failed lintel that has since been replaced.
For actively moving cracks, stitching alone won’t hold. We combine it with the underlying fix: lintel replacement, wall tie installation, drainage works, or referral to a structural engineer for foundation underpinning. We’re happy to coordinate with your engineer and provide method statements.
For builders and engineers
We frequently receive referrals from structural engineers and builders working on older Sydney stock. We work to specified bar counts, embedment depths, and grout specifications, and provide installation records suitable for the engineer’s sign-off package.
For builders working on heritage or character buildings, Helibar stitching is often the only intervention that satisfies the heritage consent, no demolition, no visible change to the facade.
FAQ
Is Helibar a permanent repair?
Yes, provided the underlying cause has been addressed. The bars are stainless steel, the grout is non-corrosive, and the system is designed for the life of the building. We’ve seen 30-year-old installations that are still completely sound.
Do I need a structural engineer first?
For smaller, clearly dormant cracks, usually not. We can diagnose and propose. For active cracks, settlement-driven cracks, or anything affecting load-bearing structure, we recommend an engineer’s involvement and we’ll work to their spec. We can refer you to engineers we work with regularly.
How many rods are needed?
It depends on crack length and severity. A typical crack of 1–2m might need 4–6 bars at staggered courses each side. We specify the count in writing as part of the quote, no surprises on site.
Get a detailed quote within 24 hours. Photos accepted via our Project Brief form.