Lockblock: the mortarless wall revolution

The Malaysian construction industry continues to face productivity challenges due to labour-intensive practices, prolonged installation time, and material inefficiencies associated with conventional mortar-based blockwork systems. This study presents the development of a mortarless interlocking blockwork (lockblock) system aimed at reducing construction time, eliminating mortar usage, and improving installation efficiency. The proposed innovation integrates three key concepts: interlocking geometry, dry-stack assembly, and lightweight material composition within an Industrialised Building System (IBS) framework. A structured design thinking methodology was adopted, comprising empathise, define, ideate, prototyping, and testing stages. The research involved a desk study of existing interlocking systems, identification of their limitations, and the development of an improved modular block design using AutoCAD and SketchUp. A 1:3 scaled prototype (200 mm × 100 mm × 100 mm) was produced using lightweight foamed concrete with a target compressive strength of 7 MPa. The results indicate that the system significantly improves installation efficiency, reduces dependency on skilled labour, enhances site cleanliness, and shortens construction duration by eliminating mortar curing time. The lightweight properties further improve handling while maintaining adequate structural performance for low-rise applications. Overall, the innovation demonstrates strong potential for sustainable and efficient construction aligned with SDG 9 and SDG 11.