Construction Five Times Faster and 50% Cheaper: 0.5 m² Blocks, 90% Smaller Mortar, and Wood-Free Beams Transform the Project; Mason Achieves 100 m²/Day

Written by Bruno Teles

Published on 02/09/2025 at 20:37

Sistema com blocos gigantes reduz 90% da argamassa, elimina formas de madeira nas vigas e permite pedreiros atingirem até 100 m² de alvenaria por dia.

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The “Giant Block” (≈0.5 m² per piece) Cuts >90% of Setting Mortar and Allows for Integration of Installations in the Holes, Which Combined with the Troughs for Beams Without Wood Enables Construction to Be Up to 5× Faster and with Up to 50% Structural Savings (in Modular Design).

The Brazilian civil construction is beginning to experience a silent revolution. A method based on blocks of 0.5 m² each promises to deliver construction 5× faster and up to 50% cheaper in the structural part, according to engineer Thiago Melo.

The secret lies in reducing the number of pieces per square meter, drastically decreasing the use of mortar, and incorporating permanent forms for beams, eliminating wood from the process.

In practice, the bricklayer goes from about 30 conventional bricks per m² to just two blocks per m², which accelerates the pace of execution. In cases of modular projects, the author cites results of up to 100 m² of wall erected in a single workday.

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How Giant Blocks Work

Construction 5× Faster and 50% Cheaper: Blocks of 0.5 m², Mortar 90% Less and Beams Without Wood Transform the Job; Bricklayer Reaches 100 m²/Day — Engineer **Thiago Melo**

Each piece covers about half a square meter and weighs around 20 kg, with smaller versions for adjustments.

The internal holes allow for the integration of water, sewage, electricity, and data pipes, eliminating cuts and rework later. This reduces material costs, execution time, and waste.

Another differential is the saving on mortar. As the joints are only between the blocks, consumption drops by more than 90% compared to traditional bricks. Additionally, the wall gains greater uniformity and fewer points of infiltration or cracking.

Beams Without Wood and Continuous Work

The system also incorporates the use of “U” Troughs that function as permanent forms for the beams.

The steel is placed inside the piece, and the concrete is poured in, with no need for wooden forms or subsequent removal. This reduces construction stages, minimizes waste, and accelerates the schedule.

According to Thiago Melo, in lightweight constructions (ground level or small-scale), it is even possible to eliminate isolated pillars, as part of the structure is absorbed by the blocks and troughs. This means more simplicity on-site and less downtime between phases.

Economic Impact and Additional Gains

In projects specifically modular for the system, savings can reach up to 50% in structural costs. In adapted projects, the average percentage lies between 25% and 30%.

Besides speed and cost reduction, the blocks offer advantages in thermal and acoustic insulation, enhancing building comfort.

Another effect is the reduction of solid waste, as the system virtually eliminates the use of wood in beams and minimizes mortar. This brings the technique closer to the sustainability goals of the construction sector.

Do you believe this model of construction 5× faster can replace traditional brick in Brazil? Do you think it’s worthwhile to invest in new construction technologies? Leave your opinion in the comments — we want to hear from those who live this in practice.

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Alcino Araujo.

#167007

03/09/2025 10:01

Bom dia , de qual material é feito o bloco e se permite bom acabamento interno,externo e assentamento de portas e janelas e se tem algum exemplo para mostrar.

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Construction Five Times Faster and 50% Cheaper: 0.5 m² Blocks, 90% Smaller Mortar, and Wood-Free Beams Transform the Project; Mason Achieves 100 m²/Day

The “Giant Block” (≈0.5 m² per piece) Cuts >90% of Setting Mortar and Allows for Integration of Installations in the Holes, Which Combined with the Troughs for Beams Without Wood Enables Construction to Be Up to 5× Faster and with Up to 50% Structural Savings (in Modular Design).

How Giant Blocks Work

Beams Without Wood and Continuous Work

Economic Impact and Additional Gains

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Construction Five Times Faster and 50% Cheaper: 0.5 m² Blocks, 90% Smaller Mortar, and Wood-Free Beams Transform the Project; Mason Achieves 100 m²/Day

The “Giant Block” (≈0.5 m² per piece) Cuts >90% of Setting Mortar and Allows for Integration of Installations in the Holes, Which Combined with the Troughs for Beams Without Wood Enables Construction to Be Up to 5× Faster and with Up to 50% Structural Savings (in Modular Design).

How Giant Blocks Work

Beams Without Wood and Continuous Work

Economic Impact and Additional Gains

Gaddafi built the world’s largest artificial river under the Sahara — it’s 4,000 km of giant pipes that pump 40,000-year-old fossil water to entire cities in Libya.

Discovery in Africa scares even scientists: a study published on April 23 reveals that the crust in Turkana has become so thin that it could pave the way for the continent’s division and the emergence of an ocean in the future, in a gigantic geological transformation.

Austria inaugurates Europe’s first high-speed railway outside China — trains travel at 250 km/h through 33 km tunnels in the Alps that took 27 years to drill

Japanese garbage collectors treat filthy trucks as if they were dealership cars, and the obsession with cleanliness is so absurd that they invented a washing machine that only exists for this type of vehicle.

An unmanned Russian ship has been drifting in the Mediterranean for 57 days with 60,000 tons of gas — the second towing attempt has just failed.

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