Bespoke special shaped bricks
Precision and creativity in clay
At Ketley Brick, we understand that exceptional architecture often demands more than standard brick formats. That’s why we offer a bespoke extruded brick service, enabling architects and designers to achieve unique shapes, profiles, and details that bring their visions to life.
Our cost effective extrusion process allows for the creation of custom shapes in both small and large quantities. Whether you need special angles, curves, chamfers, or intricate profiles, our team works closely with you to design and manufacture bricks to turn your ideas into reality.
How It Works
- Consultation & Design – Share your concept or technical drawings with our team.
- Prototype & Approval – We produce samples for review.
- Production & Delivery – Once approved, your bespoke bricks are manufactured to the highest standards and delivered ready for installation.
From complex façade details to heritage restoration projects, Ketley’s bespoke extruded bricks provide the flexibility and craftsmanship needed to achieve truly outstanding results.
Case Studies
Portal buildings at Silvertown Tunnel
The Silvertown Tunnel Portal Buildings in London, designed by dRMM Architects, use Ketley Staffordshire blue bricks and bespoke bullnose specials to create striking chain-link patterned façades that visually link the two structures. Built to last for centuries, the buildings combine sculptural forms with durable Class A engineering bricks, ensuring both aesthetic impact and long-term performance. The project, executed by AVV Solutions, won the 2025 Brickwork Contractors Best Project Award for its meticulous craftsmanship and innovative brickwork design. Full details
Mixed Use development at Glengall Rise, Peckham
Glengall Road is a mixed-use development in Southwark, London, featuring 170 affordable homes and flexible workspace, designed by AHR Architects for Southern Housing Group. Built on the historic site of the R White’s Lemonade and Edison Bell factories, the scheme preserves key industrial features including the original warehouse façade and chimney. Ketley’s Staffordshire blue bricks were used extensively to reflect the site’s heritage, with over 155,000 bricks, including bespoke wavy specials, which add a striking contemporary detail. Full details
Textured brickwork extension
This inspiring project by Mulroy architects uses Ketley plinth bricks and returns to create a wonderful textured wall to a new extension on this North London Victorian property. The architects used the bricks in a most innovative way to create a decorative gothic fluting pattern which brings shadow and texture. Find out more about this project here
Environmental
Place of Manufacture: Brierley Hill, UK
Environmental Management: 14001 Download Certificate
Quality Management : 9001 Download Certificate
Download the Ketley Quality and Environmental Policy
Life Cycle: BRE Global Certification in accordance with EN 15804:2012 Download Certificate
Energy: Cured in gas fired kilns to 1130o C
Raw materials: Etruria Marl Clay from our local quarry in Brierley Hill, sand
Lifespan: Ketley's bricks are the toughest and most durable bricks you can buy.
Recyclability: Can be crushed and used as aggregate and/or as an inert bulk fill
Packaging: We keep packaging to a minimum using wooden pallets and we do not shrink wrap our brick packs.
Find out more about Ketley's approach to sustainability
Click for the Brick Development Association infographic on Sustainability of Brick
See below the latest video about Sustainability of Brick from the Brick Development Association
Technical Specification
Ketley Brick Specification Sheet
Standard: BS EN 771-1: 2011
Ketley Bricks are produced at our works located in the heart of the Black Country. They have been made from our own Etruria Marl since Victorian times and are recognised as a Class A engineering brick of high quality with a strong aesthetic appeal.
Download Specification sheet as pdf.
Download Specification clause as a word doc
Download water absorption and compressive strength test report for solidsDownload water absorption and compressive strength report for perforated bricks
Ketley is the only brick manufacturer to have had their bricks independently tested for freeze thaw performance within a textured facade, with bricks within the test panel projecting up to 50mm. The test was based on prEN772-22 and no damage was found on any of the bricks tested.
Download textured brickwork freeze thaw test report
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Compressive strength: |
≥ 125N/mm² |
≥125N/mm² |
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Category: |
II |
II |
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Masonry Unit Group: |
HD |
HD |
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Engineering Grade: |
A |
A |
|
Water absorption: |
≤4.5% |
≤4.5% |
|
Initial Rate of Water absorption: |
≤1.5Kg/m²/min |
≤1.5Kg/m²/min |
|
Thermal Conductivity: |
On Application |
On Application |
|
Bond Strength: |
0.15N/mm² (For general purpose and lightweight mortar) |
0.15N/mm² (For general purpose and lightweight mortar) |
|
Net Dry Density: |
2200 Kg/m³(Typically) |
2200 Kg/m³(Typically) |
|
Density Tolerance: |
D1 |
D1 |
|
Soluble salt content: |
S2 |
S2 |
|
Durability: |
F2 |
F2 |
|
Fire Reaction: |
A1 |
A1 |
|
Dimensional Tolerance Mean: |
T2 |
T2 |
|
Dimensional Tolerance Range: |
R1 |
R1 |
Special Shaped Bricks
Special Shaped Bricks
Because Special Shaped bricks are generally used in situations of severe exposure such as copings and cills, powerful resistance to water penetration and high durability has always been essential.
Ketley Bricks are generally solid and have stood the ultimate test, the test of time. In the early part of the 20th Century their blue colour was regarded as the stamp of durability, nowadays their performance under crushing tests, water absorption and abrasion tests is evidence of this.
The use of Ketley Specials to add a high quality finish to brickwork ensures extra durability and protection to vulnerable areas and will save time on-site by overcoming extensive hand cutting.
Download Special Shaped Brick Brochure
or browse our range of specials online
Consistent natural colours
Our unique plant produces traditional natural Staffordshire clay colours for both the Paver and Brick ranges in Blue, Brown Brindle and Red. Because our bricks, pavers and specials are fired together, our colours are consistent through the range.
Ketley Brick manufactures a wide range of special shaped bricks for a multitude of applications.
Ketley will also manufacture specials from drawings supplied, allowing you to explore imaginative design options and decorative detail, confident that Ketley will be able to acurately match requirements.
