4-3: PRODUCTIVITY IN CONCRETE MASONRY CONSTRUCTION

Introduction

The construction industry is one of the largest segments of the national economy.
Spiraling costs during recent years have emphasized the need for improving
productivity in all aspects of construction. Since the cost of masonry accounts for
more than five percent of every dollar spent in building, the National Concrete
Masonry Association and other industrial organizations joined with the U.S.
Department of Housing and Urban Development in sponsoring an experimental
investigation of the restraints on mason productivity.

The project was carried out by the Center for Building Research, College of
Engineering, University of Texas. Guidance for the project was provided by a
National Advisory Committee on Mason Productivity, composed of representatives
from national societies of design professionals, contractors, product manufacturers,
labor organizations, and the federal government.

Scope of the Project

A technical literature search, an industry opinion survey, and an experimental measure

of productivity, made up the investigation. The scope of the literature search was
world-wide, and produced useful information from Western Europe as well as the
United States. The literature review reduced the possibility that the experiments might
duplicate previous research efforts.

The industry opinion survey was accomplished through questionnaires and personal
interviews. The survey was conducted to determine the variations in attitude of labor
and industry groups, and the restraints that these organizations place on mason
productivity.

The experimental phase of the study was designed to measure the effect of the most
important factors influencing mason productivity. Included in the variables evaluated
were: unit size and weight; mortar type and joint thickness; wall size, type, and
bonding pattern; scaffolding, corner poles and mechanical devices; workmanship,
weather fatigue factor.

During the experimental phase of the project, 283 masonry test panels were
constructed. Two crews, each consisting of two masons and one mason tender, were
assigned to construct two panels daily: one in the morning, and one in the afternoon.
Test panels were designed to approximate the amount of work that one mason
working alone could complete in an eight-hour day. The productivity of the two
masons were averaged for each test panel. To stimulate actual construction conditions,
all test panels were built on a concrete slab provided especially for the project. No
shelter was provided for the masons in order to exposed them to the weather.

The experimental investigation was designed to accumulate a basis of valid data for
statistical analysis. Sufficient panels were constructed at various times throughout the
year so that a wide range of weather conditions, and other physical variables affecting
productivity were included. In most cases each variation in construction was repeated
five times to assure statistical reliability. The experimental data from test panel
construction were studied through a computer program, and were evaluated using
recognized statistical procedures.

Experiments and Findings

Unit Size

Test panels were constructed from concrete block, clay tile, and brick. Productivity
was found to be directly affected by the size of the masonry unit employed. In general,
the amount of wall laid per day increased with the unit size. Table 1 summarizes the
test findings. Because actual productivity depends on numerous variables, Table 1 also
lists relative productivity using standard size brick productivity as a base of 1.00.
Highest value, obtained with 6x8x16 concrete masonry units, was 3.29 time more
productive than with standard brick.

Table 1 - Productivity with Various Masonry Units

Unit Wall
Description Size & Weight Surface ARea Nominal Productivity Sq. Relative
Type lbs. sq. ft. Thickness in. ft./8hr. Productivity
4" x 2 2/3" x 8" std. -- 4 160* 1.00
brick -- 0.148 4 207 1.28
4" x 2 2/3" x 12" -- 0.222 4 218 1.36
Norman brick -- 0.222 4 242 1.51
4" x 4" x 8" Economy 13.7 0.333 8 257 1.61
brick 8.6 0.444 4 266 1.66
4" x 4" x 12" Economy 12.4 0.444 6 287 1.79
brick 15.2 0.444 4 308 1.93
8" x 5" x 12" Hollow 25.3 0.667 8 360 2.25
tile 31.9 0,667 12 376 2.35
4" x 5" x 12" Hollow 26.2 0.889 8 467 2.92
tile 16.4 0.889 4 494 3.09
6" x 5" x 12" Hollow 21.1 0.889 6 526** 3.29
tile 18.9 0.889 4 13 258
4" x 8" x 12" Hollow 34.9 1.000 8 245*** 1.53
tile 1.333
8" x 8" x 12" Hollow
 tile
12" x 8" x 16" Hollow
block
8" x 8" x 16" Hollow
block
4" x 8" x 16" Hollow
block
6" x 8" x 16" Hollow
block
4" x 12" x12" Hollow
tile
8" x 8" x 24" Holow
block
* lowest value
** highest value
*** Because of local union regulations concerning size of units, two masons to handle each unit were used eve
though the weight of the unit did not require two masons. The result was a drastic drop in productivity for this size.
THIS SIZE REGULATION IS NOT A UNION RULE APPLIED NATIONALLY.

Unit Weight

Unit weights of brick were not evaluated for effect on productivity because of the
small size and relatively same density. Unit weights of clay tile and concrete masonry
are shown in Table 1. In relating unit weight to productivity, no significant reduction
occurred as unit weight increased, except when extremely large units were used. Only
then did unit weight appear to increase mason fatigue and thereby lower output.

Mortar Type

Test panels were constructed using mortar made from portland cement and lime.
Types M, S, N, and O were mixed to meet the requirements of ASTM C 270,
Specifications for Mortar for Unit Masonry. The sand content of the mortar was not
varied within the allowable ASTM limits. The possibility of obtaining increased
productivity from better mortar workability was therefore not evaluated. Of the
mortars used, none exhibited any significant effect on mason output.

Joint Thickness

The standard 3/8 inch mortar joint was used extensively in constructing the test
panels. In additions, a 1/2 inch joint thickness was used for construction of some brick
panels. A 15% decrease in productivity resulted from using the 1/2 inch joint thickness
was used for construction of some brick panels. A 15% decrease in productivity
resulted form using the 1/2 inch mortar joint. This was attributed to the fact that the
masons were accustomed to using the standard 3/8 inch mortar joint; when the joint
thickness was increased, the masons concentrated more on picking up extra mortar, or
used two motions instead of one to achieve the desired thickness.
It was also determined that fewer joints per square foot of wall area has the same
effects as reducing joint thickness. As the sized of the masonry unit increases, fewer
motions are required to form the joints.

Wall Shapes and Sizes

Masonry panels were built to various heights and widths in order to simulate actual
job conditions. The variations in configuration of the walls did not tend to decrease
productivity until the walls became narrow, and in effect required the mason to
construct a column.

Composite Walls

Tests of composite walls were made using brick facing and concrete block or clay tile
for the back wythe. The results are shown in Table 2. The use of concrete block as the
back-up increased productivity at least 8% above the highest values attainable with
clay tile.

Table 2 - Composite Wall Productivity

Construction Productivity Sq. Ft./8r.*
Brick and 4 x 8 x 16 in. CMU 194
Brick and 8 x 8 x 16 in. CMU 190
Brick and 480 Tile 169
Brick and 6T Glazed Tile 140
Brick and 880 Speed Tile 174
*Based on area of both faces of wall.

Scaffolding

The type of scaffolding used in the construction of the test panels had a significant
effect on productivity. Two types of scaffolds were tried. The most popular type,
known as tubular scaffolding, consists of tubular frames with adjustable supports. The
supports are moved to raise the working platform to convenient heights. The second
type, called tower scaffolding, has a continuous incremental adjustment feature. This
feature keeps the mason positioned at the ideal level, and minimizes fatigue by
reducing the bending required of the body. The test results 19% increase in production
with the use of tower scaffolding in comparison to the conventional tubular frame.

Corner Pole Arrangements

The use of corner poles resulted in an increase of approximately 9% in mason

productivity in comparison to building leads. The corner pole application was used in
constructing low-level walls. It was recognized that the technique would not be
practical on high-rise construction because of the difficulties involved in keeping the
poles plumb and true.

Mechanical Mortar Spreader

Use of a mechanical mortar spreader in tests performed with 8x8x16 in. concrete
block, showed an increase in productivity of approximately 56%. It was recognized,
however, that mortar spreaders have limited application and that comparable results
cannot be expected in all cases.

Workmanship

To evaluate the effect of workmanship on productivity, five test panels were

constructed without using a system of inspection. The balance of the test panels were
built utilizing an inspection system similar to the type used on actual construction
projects. A 64% increase in productivity resulted from the uninspected construction,
but the quality of the workmanship was less than desirable.

Overhand Construction

In overhand construction, masonry walls are laid up by scaffolding and working from
one side only, even though both wall faces may be finished surfaces. The mason lays
up several courses of the inner wythe, and then reached over them to build the outer
wythe up to the same level. The reaching strains the mason and makes it more
difficult to maintain true lines and levels. Use of the method during the test showed a
productive decrease of 18%.

Surface Bonding

Surface bonding is a recently developed mortar system. It uses a product basically

composed of portland cement and glass fibers for reinforcement and increased tensile
strength. In the surface bonding system, concrete block are stacked dry to form a wall
without mortar in the joints. The wall is then plastered with the surface bonding
mortar. Test panels were built with both standard and ground concrete block to
determine the effectiveness of the system. The resulting productivity was 70% greater
than that achievable with a conventional mortar system.

Weather

Wall panels for the study were constructed outdoors between August 1971 and April
1972, to evaluate actual working conditions. Wind, temperature, and humidity were
recorded to determine the effect of each. Wind speeds were generally less than four
miles per hour, hence no significant effect on productivity was observed.

The combined effect of temperature and humidity on mason productivity is

summarized in Table 3. Productivity factors were tabulated for combinations of
temperature and humidity. The highest factor attainable under any conditions was .
973, and occurred at 75 F. and 60% relative humidity. The factor was less than
unity because of allowances for nonproductive time in the calculations.

The table can be used to predict mason productivity as influenced by weather

conditions. The average temperature and humidity for working hours in a locality may
be obtained from "Local Climatological Data," published by Environmental Science
Service Administration.

Using the expected temperature and relative humidity, a productivity factor can be
extracted from Table 3. For example, if the temperature and relative humidity for a
given month are determined to be 55 F and 60% relative humidity, the productivity
factor from the table is .747. Assuming that a mason could lay 170 8 x 8 x 16 in.
concrete masonry units a day under the best weather conditions, then for the given
month he could be expected to average .747 (170) or 127 units per day.

Table 3 - Productivity Factors

Relativity Humidity (%) 45 55 65 75 85 95
90 .635 .671 .717 .727 .640 --
80 .650 .710 .765 .795 .760 --
70 .675 .740 .816 .930 .680 --
60 .670 .747 .820 .973 .673 --
50 .655 .727 .790 .908 .765 .623
40 .614 .685 .742 .768 .697 .615
30 -- .628 .667 .670 .648 --

Fatigue Factor

Panels were constructed in the morning and in the afternoon by the same crew of
masons. Observations were made to determine the effect of fatigue as the work-day
progressed. It was found that no significant reduction in output could be attributed to
fatigue, and in fact the afternoon rate of production tended to be higher than the
morning rate.

Recommendations
Labor is a significant cost factor in the current construction market. Consequently, all
means available for increasing masonry production should be fully utilized.

The data and results obtained from this study provide valuable information on the rate
of mason productivity. By incorporating these findings in the design and construction
of masonry projects, both the architect and the contractor can help achieve cost
reduction.

http://yanpage.narod.ru/NCMA_TEKs/TEKs/Wce2dc5fd190ee.htm

Abstract
The aim of this paper is to report on measuring labor productivity for block
works on building projects in the Gaza Strip by using activity sampling for
block works. The labor productivity measurement on construction sites was
based on studying block work in the Gaza Strip. In this research activity
sampling technique has been chosen. Data for this study was collected from
construction sites of sheikh Zayed township project through observations.
This township project includes 70 five-story buildings, 5 twelve-story
buildings, a mosque, a school, shops, offices, and two water reservoirs. It
includes also the construction of infrastructure works. The results indicate
that the average productivity rate of skilled labor in laying blocks 20 is 38.40
blocks per hour (3.07 m2/h), while average productivity rate of skilled labor
in laying block 10 is 40.50 blocks per hour (3.24m2/h). The research looked
at the distributions of skilled labor time and unskilled labor time in working
day. The finding also indicate that productive time of skilled labor was 77% of
his working time, while productive time of unskilled labor was 9.34% of his
working time. It is hoped that this research will lead to an improvement of
the construction productivity in Palestine and other developing countries..
https://www.researchgate.net/publication/268267879_LABOR_PRODUCTIVITY_MEAS
UREMENT_IN_BUILDING_PROJECTS