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Development and Delivery of a

Concrete Masonry Design and Construction

Course

FINAL REPORT

May 21, 2014

Dr. Thomas Nicholas, P.E.

Dr. Tara L. Cavalline, P.E.

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Introduction

Previously, the Department of Engineering Technology and Construction Management at the

University of North Carolina at Charlotte (UNC Charlotte) has not offered a course in masonry

design or construction. With Charlotte, North Carolina being one of the largest metropolitan

centers in the south, there was a need to provide an educational foundation to graduating seniors

and graduate students on concrete masonry design and construction.

The funded proposal has provided support in the development and offering of a course entitled

“Masonry Design and Construction” at UNC Charlotte. This course was offered during the

Spring 2014 semester as a senior elective course to UNC Charlotte’s Civil Engineering

Technology and Construction Management students, as well as to graduate students in the UNC

Charlotte’s Masters in Construction Management and Facility Management program. The course

was designed/developed to address masonry design and construction in both the classroom and

laboratory.

Course Modules

A primary objective of this project was to develop a modular course that could be easily

implemented at other institutions. Furthermore, the course had to be structured to provide an

even distribution of design and construction while catering to both senior level students and

graduate students. In order to achieve the level of instruction for both constituents and provide a

modular course, the instructors have developed an innovative approach to the classroom, termed

course modules. Course modules are based on the eleven course objectives (listed in Table 1)

that were covered in the class

The undergraduate students were required to complete each course module at the appropriate

instructional level (undergraduate or graduate, with appropriately scoped accompanying exams)

for successful completion of the course. The graduate students had to complete the course

modules; however, they were asked to perform additional work for successful completion of the

course.

The significance of course modules is that each module is objective specific and objectives can

be added or taken away to customize specific course or university requirements. Furthermore,

one or two modules can be used in a training environment providing flexible use of the material.

Table 1 Learning Objectives: 1.) Demonstrate understanding of basic masonry materials and their history.

2.) Demonstrate understanding of basic masonry construction practices.

3.) Demonstrate understanding of mortar properties and joint properties.

4.) Demonstrate understanding of basic masonry inspection practices.

5.) Demonstrate understanding of where, when, and why to use a masonry structure.

6.) Analyze and design unreinforced concrete masonry structures using code requirements.

7.) Understand how to calculate the compressive behavior of concrete masonry.

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8.) Understand how to calculate the flexural strength of concrete masonry for each design

element.

9.) Analyze and design reinforced concrete masonry beams using code forces.

10.) Analyze and design reinforced concrete masonry walls and columns using code forces.

11.) Analyze and design reinforced concrete masonry walls and shear walls.

Course Delivery

The course was delivered to 20 students (15 undergraduate and five graduate students), and was

deemed by both instructors and students as a success. In all, six course modules were developed

to cover the eleven learning objectives listed in Table 1. The Course Module list is as follows:

1. Course Module 1

a. Demonstrate understanding of basic masonry materials and their history.

b. Demonstrate understanding of basic masonry construction practices.

2. Course Module 2

a. Demonstrate understanding of mortar properties and joint properties.

b. Demonstrate understanding of basic masonry inspection practices.

c. Demonstrate understanding of where, when, and why to use a masonry structure.

3. Course Module 3

a. Analyze and design unreinforced concrete masonry structures using code forces.

b. Understand how to calculate the compressive behavior of concrete masonry.

4. Course Module 4

a. Understand how to calculate the flexural strength of concrete masonry for each

design element.

b. Analyze and design reinforced concrete masonry beams using code forces.

5. Course Module 5

a. Analyze and design reinforced concrete masonry walls and columns.

6. Course Module 6

a. Analyze and design unreinforced and reinforced concrete shear walls.

The objective of the lecture portion of the course was to introduce students to design of masonry

walls, beams, columns, and foundations, and to familiarize students with applicable codes and

standards. The class performed very well in the lecture portion of the course with many earning

high marks in the analysis and design of masonry systems. Most students recommended that we

continue to offer the class for future students. All 20 students successfully completed the class

with exam averages of 84% for the first exam, 81% for the second exam and 78% on the final

exam. The final grade average in the class was an 84%. While the lecture received high marks,

the students had the most praise for the course management style (Course Modules) and the

laboratory. The class provided very positive feedback on the mixed lecture and lab style course

which in academia would resemble a “just-in-time” course delivery format. In order to aid in

the students understanding of masonry systems and design, a site visit to a local construction

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project was scheduled that utilized both CMU and clay masonry building systems, illustrated in

Figure 1. The commercial building was designed to be a multi-unit complex for student housing.

Due to the multiple buildings located on the site at different stages of construction, the students

were provided with a unique experience in visualizing the building process.

Figure 1. Masonry Course Construction Site Visit

The objectives of the laboratory portion of the course was to introduce students to laboratory

tests used in quality assurance and control of masonry construction and to provide students with

the opportunity to learn masonry construction techniques by constructing large-scale mock-ups

in a laboratory setting. By far, the students responded most favorably to the lab component of

the course. Every student was engaged during lab and eager to participate as illustrated by

Figure 2. The lab average for the class was 86% and the final project report average was a 90%.

The following labs were performed during the spring semester:

1. Introduction to Masonry Materials (1 Laboratory)

2. Aggregate Characterization for Masonry Mortar and Grout (2 laboratories)

3. Masonry Mortar (2 laboratories, Figure 2)

4. Masonry Grout (2 laboratories)

5. Masonry Prism Test (2 laboratories)

6. Masonry Construction Demonstration and Training (1 Laboratory, Figures 6 and 7)

7. Full Scale Masonry Wall and Construction (4 laboratories, Figure 3)

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Figure 2. Compressive Strength Testing of Mortar Cubes - ASTM C109

Since both graduate students and undergraduate students were enrolled in this course, a unique

pedagogical opportunity existed. For each laboratory exercise, the students were broken into

groups led by a graduate student. This allowed for all undergraduate students to work with and

be mentored by high-performing, more experienced students during both the in-class procedures

and in development of laboratory reports. This also provided an opportunity for graduate

students to serve as team leaders, using project management skills to lead the work effort of the

group. Overall, this format aided in enhancement of the overall quality of work performed and

submitted in the laboratory portion of this course.

Semester Project

The Masonry Design and Construction students were tasked to perform the following to

construct the masonry wall illustrated by Figure 3:

For the semester project, we will be using two materials for mortar: LWA and Sand. In

the interest of time, the laboratory testing will be divided amongst the following two

groups:

Mortar Mixture CMU Fine Aggregate Group Members

Sand Lightweight,

Standard 8x16

Normal weight

natural sand

Student

LWA Lightweight,

Standard 8x16

Light weight

aggregate

Student

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Assignment:

The goal of this exercise is to successfully construct and test to failure, a 24” x 72” CMU

hollow wall. The parameters of your design will be f’m = 1000 psi, lightweight block and

a mortar test strength similar to type S.

Objectives:

1. Calculate the design capacity of the wall in the same manner as performed in Course

Module 3. Make sure to calculate the code values and a value that does not include safety

factors.

2. Construct the wall, making sure to construct three prisms to serve as companion

specimens for determination of the true f’m.

3. Graduate students only:

a. Design wall instrumentation - Hardware

b. Provide instructor with instrumentation needs list for ordering

c. Design wall instrumentation – Software

d. Perform trial test using Instron® for load and deflection

e. Instrument wall

4. Full scale test of wall to failure

Figure 3. Test Specimen Dimensions and Detail (Student Final Report)

As most of the students (and instructors) were unfamiliar with constructing masonry walls, UNC

Charlotte partnered with CCMA and Gates construction to provide a Masonry Construction

Demonstration and Training day. The Master Masons, shown in Figure 4, donated their time and

skill to train the class on the proper way to construct a CMU wall. The Masons discussed

troweling techniques, leveling, inspection practices and construction tolerances while building a

mock-up wall for the class. An emphasis was placed on quality assurance and control

considerations utilized in practice. Once the demonstration was complete, the students built a

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mock up wall resembling the wall they would build for the semester project as shown in Figure

5.

Figure 4. Master Masons from Gates Construction - Masonry Construction Demonstration

and Training

The class was divided into two teams each consisting of graduate and undergraduate students for

the semester project. As previously stated, team one constructed a lightweight system utilizing

lightweight unreinforced wall system and team two constructed a normal weight unreinforced

wall system shown in Figure 6 (right picture). Team one’s wall (Wall Test #1), experienced a

localized crushing failure at the load application location that produced a maximum load of

21,489 lbs (Figure 7) which was well short of the predicted value of 51,300 lbs. It should that

the wall capacity of Wall #1would have been greater than recorded; however, due to safety

concerns after the crushing failure the test was aborted. Team two’s wall (Wall Test #2) (Figure

6), produced a maximum load of 59,141 lbs which represents a 13% increase over the theoretical

value determined to be 51,374 lbs (Figure 8).

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Figure 5. Students Learning to Construct CMU Wall - Masonry Construction

Demonstration and Training

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Figure 6. Before Failure (Left) and After Failure (Right) of Full Scale Wall Test #2.

Figure 7. Load-Displacement vs. Time for Wall Test #1

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Figure 8. Load-Displacement vs. Time for Wall Test #2

Conclusions

In closing, the course was a success for the students, instructors and the Department. Student

reviews for the course quantitatively was a 4.83 out of 5 for both “overall, I learned a lot in this

course” and “overall course evaluation.” Qualitatively, the students had the following

statements:

“I wish I had more classes like this. The lecture/lab format worked very well.”

“Dr. Nicholas and Dr. Cavalline are great teachers, I really enjoyed this course and

Masonry!”

“This was a fast paced course, loved the lecture/lab format.”

“We should have more classes like this.”

“Masonry should be a required course here, I’m going to recommend it to everyone.”

While the preceding statements only represent some of the student comments, all student

comments were very positive and similar to the comments provided. The course is planned to be

placed on the rotating elective course offering in the department with hopes from the instructor

of a permanent place in the curriculum.

Attachments

As part of the final report submission, digital copies of each Course Module that contains:

1. PowerPoint® Lecture

2. Required Reading

3. Homework Assignment

4. Laboratory Procedure