1. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
“Design and Construction of
Mortarless Interlocking Masonry”
Prepared by:
Jesse Edwards, Mina Gayed,
Michael Pyra, & Tisbeth Rodriguez

2. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Goals
 Part I
– Introduction: what is mortarless masonry?
– Why was it introduced and what are its benefits?
– Currently available systems
– Design example
 Part II
– Construction aspects
• Applications and limitations
– Productivity and cost comparisons
– Case study

3. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Introduction: What is mortarless masonry?
 Eliminates the use of mortar
in head and bed joints
 Geometric interlocking
mechanisms
 Reinforced and grouted
 Post-tensioned and surface
bonded
 Manufactured with tighter
tolerances for alignment

4. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Current Systems Available
Name of System
(Country, Year)
Block Type
(Material)
Interlocking
Mechanism
Reinforcement
Type
Haener (USA, 1975) Hollow (concrete)
Nibs in bed joint, T&G
in head joint
Vertical &
horizontal
Sparlock (Canada, 1986) Hollow (concrete)
Geometric interlocking
and stacking
Vertical
Mecano (Peru, 1998) Hollow (concrete) No interlocking*
Vertical &
horizontal
Sparfil (Canada, 1989)
Hollow (light-
weight concrete)
No interlocking* None
Whelan-Hatzinikolas-
Drexel (USA, 1992)
Hollow (concrete)
Rounded dovetail lug on
head joint
Vertical
Azar (Canada, 1997*) Hollow (concrete)
3 mechanisms: web key,
head and bed joint face
shell interlocking
Vertical &
horizontal
Silblock (India, 1999) Solid (concrete) Geometric interlocking Vertical

5. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Masonry Statistics
 60% of traditional masonry construction is skilled labour
 Average age of a skilled mason in the U.S.A. and Canada is
56 years old. (National Concrete Masonry Association)
– Influx of young skilled masons in industry is decreasing
 Traditional crew consists of 3 masons and 1 labourer; the
crew is reversed for mortarless masonry
 Ex: Construction of house foundation
– 3 unskilled labourers can construct a 1,200 block foundation in 4-5 hours
Up to 10X faster than traditional masonry and cast in place concrete!

6. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Some Benefits
 Significant labour savings
 Contractors win  owners win
 Multitude of applications: commercial, industrial, and
residential projects
 All weather construction
 Fuels masonry growth in
the building sector
 Establish masonry as
a competitive material!!

7. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Design Aspects
 Given a shear wall:
– 200 mm block, fully grouted
– 3.2 m long and 10.0 m high
– Dead load: 300 kN
– Shear: 200 kN & moment of 1200 kN-m
 Given a flexure wall:
– 200 mm block, fully grouted
– 4.0 m high
– Dead load: 150 kN/m
– Live load: 100 kN/m
 Design with 30 MPa blocks for both the
traditional and Azar systems using vertical
reinforcement of 15M bars @ 400 c/c

8. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Design Aspects
Shear Wall Flexure Wall (per meter)
Traditional Mortarless Traditional Mortarless
Axial Resistance (kN) 3348 4315 1047 1348
Moment Strength (kN-m) 1660 1680 19.5 22.3
Shear Reinforcement
Yes (15M at
600mm c/c)
No N/A N/A
Diagonal Shear (kN) 270 480 N/A N/A
Sliding Shear (kN) 542 542 115 115
Mortarless masonry is equal to or exceeds traditional
masonry strength!
Note: Mortarless values are based on Azar Block design.

9. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
PART II - Construction

10. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
“Traditional” Applications
 The North American market:
– Haener: individual consumer use (primarily Los
Angeles), variable commercial applications
– Sparlock: firewall construction
– Azar: house foundations and firewall construction
 The untapped potential of these systems is huge
 Large industrial and commercial applications of these
systems have only become more common in the last
decade

11. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Integrated Systems
 Integrated Masonry Systems Inc.
(IMSI): cavities for insulation and
electrical wires
 Durisol and Faswall: Portland cement
and mineralized wood fibre for high
R-value and ease of handling
 Primarily residential applications
IMSI
Faswall

12. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Limitations
 Regional building code restrictions
– Ex: Azar Block review by the Canadian Construction
Materials Center (CCMC) for compliance with NBCC:
• Buildings up to 3 storeys and an area of 600 m²
• Wall construction must be fully grouted
• Basement walls cannot exceed 2.5 m in height
• Exterior above-grade walls and interior load-bearing walls
are limited to 20 times the wall thickness
 Challenges posed by high initial settlement and
attaining plumb

13. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Productivity and Cost Comparison
 Two identical commercial buildings in Edmonton, AB;
one built traditionally and the other with the Azar
system:
– 15 m (W) x 50 m (L) x 4 m (H)
– 200 mm x 200 mm x 400 mm units
– 20M vertical bars at 600 mm spacing
– Grouted every third core (Azar fully grouted)
– Traditional team: 3M-1L (30 blocks/hr)
– Azar team: 1M-3L (300 blocks/hr)

14. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Productivity and Cost Comparison
Time = 1377 hrs (34.4 wks) Time = 505 hrs (12.6 wks)
$141,174
$212,511
$888
Material
Labour
Equipment
$189,360
$76,073
$2,536
Material
Labour
Equipment
$141,174
$189,360 Traditional
Azar
$212,511
$76,073
Traditional
Azar
Material Comparison Labour Comparison
Traditional Construction = $354,573 Azar Mortarless System = $267,969

15. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
 2,952 sq. ft. residence
 Built in 2006
 FlexLock Wall System
 Post-tensioned walls
Case Study: Magnolia, Texas

16. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Case Study: Magnolia, Texas
Laying the First Two Courses
Dry-Stacking the Walls

17. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Case Study: Magnolia, Texas
Pouring the Bond Beam Tensioning the Wall

18. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Case Study: Magnolia, Texas
 FlexLock performed a comparative cost analysis based
on installed cost of standard 8" masonry in the region:
– Total masonry costs declined by 24%
– Productivity increased by 120%.

19. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
 Condos in Bois-
Franc Community,
Montreal
 Constructed using
the Sparlock
Interlocking
Building System
Mortarless Construction in Canada

20. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
 Besser Proneq machine
shop in Quebec City
 Sparlock blocks use for
the building envelope
Mortarless Construction in Canada

21. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Conclusion
 The structural capacity of mortarless blocks is
comparable to standard concrete masonry units
 Not suitable for all applications
 Mortarless construction is more efficient and cost-
effective than conventional masonry
 Mortarless units are becoming more readily available
and have been implemented in many projects around
the world

22. MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Questions?
Sacsahuaman, Peru -1423 A.D.
“ Arguably, the biggest change in the world of concrete masonry
units is the mortarless system.”
(Masonry Magazine)