Conventional concrete masonry construction consists of an assemblage of concrete blocks, mortar, grout, and steel reinforcement. While effective, this constructive method is constrained by its low productivity. In recent decades, advances in construction and manufacturing technologies now allow for the production of larger and more complex block typologies, enabling designers to reassess conventional designs to optimize structural performance and construction efficiency. As such, this study introduces the “mega-interlocking block”, a novel block that integrates the benefits of mega blocks (i.e., blocks with larger sizes) with a newly designed interlocking mechanism to enhance structural performance and expedite the construction of masonry walls in work sites where forklifts, scissor lifts and other smaller crane equipment are available. A numerical study was conducted to evaluate the in-plane (IP) and out-of-plane (OOP) behaviors of masonry walls constructed with mega-interlocking blocks, including both unreinforced masonry (URM) and reinforced masonry (RM) configurations, compared to standard block walls. A simplified micro-modeling approach was utilized to account for various possible failure modes associated with masonry structures. Results indicate that mega-interlocking blocks significantly improve wall stiffness and load-bearing capacity under IP loading, both with and without mortar, outperforming standard block walls. Under OOP loading, interlocking blocks provide moderate performance gains when mortar is present, though their effectiveness diminishes in mortarless configurations. For URM walls under IP loading, the implementation of mega-interlocking blocks yielded substantial improvements in stiffness and capacity, with the most notable benefits observed in walls with larger aspect ratios. Although the relative advantages in RM walls were less pronounced due to the homogenizing effects of grout and reinforcement, mega-interlocking blocks still demonstrated robust structural performance, making them a promising alternative to standard masonry units.
Labib et al. (Sun,) studied this question.