🚧 Under construction — VoTechWorks is being built. A free tech program — complimentary, as our commitment to get America working.
voTechWorksGrade 13 · a vocational technology learning center, by urbanicity
newSchoolWorks.com › VoTechWorks › Building & Construction › Masonry › Layout & Leveling › Lesson 6
BLD-MASO04-10 · Lesson 6 · 14 clock hours · practice

Story Poles, Course Layout, and Plumb Control

Objective. Students will fabricate a story pole scaled to actual brick or block coursing dimensions and use it with a plumb bob and level to lay out and verify course heights and plumb on a practice wall section.

⚠ Pending professional review

This lesson, its worked examples and its practice questions has not yet been verified by a licensed professional engineer or master tradesperson or by a certification or approval body. It is a study draft and may contain errors. Do not use it as instructions for work on a job site or on live equipment. Always follow your instructor, your supervising professional, and current official references and regulations.

VoTechWorks program approval and accreditation are still in progress. Credentials are issued only by the certifying bodies named in each program, after their own exams.

Why Story Poles Matter

A story pole is a length of wood — typically a 1×2 — marked with every course height for a given unit and joint size. It is one of the oldest and most reliable layout tools in masonry because it eliminates cumulative arithmetic error. Instead of measuring each course independently with a tape, you hold the pole against the wall and read the marks. Every course is compared to the same reference line that was drawn once and confirmed against physical units. NCCER Masonry Level 2 identifies story pole layout as a core competency, and journeyman masons use poles on every significant wall run.

Course Height Fundamentals

Course height equals the unit height plus one mortar joint. Two common combinations define the marks you will make:

Always confirm against the physical unit you have in hand — manufactured units vary slightly, and your story pole must match reality, not just a textbook number. Lay a sample unit on a flat surface, set a joint guide or folded cardboard to the specified joint thickness, and measure the combined height with a combination square or tape. That confirmed dimension is what you scribe onto your pole.

Fabricating the Story Pole

1. Select a straight 1×2 long enough for your coursing sequence — for eight courses of brick at 3 inches each you need at least 24 inches of marked length; for eight courses of 8-inch CMU you need at least 67 inches.

2. Mark course zero at one end with a heavy pencil line and label it "0 / Grade."

3. Step off each course using a combination square set to the confirmed course height. Never chain-measure from the previous mark alone; reset your square from the master mark periodically to prevent drift. Mark lightly first, then confirm and darken.

4. Label every mark with its course number (C1, C2 … C8) and the cumulative height in inches (3", 6", 9" … 24" for brick).

5. Verify by placing the finished pole beside a stacked column of actual units (dry-stacked with cardboard joint simulators). The marks should align with the top of each unit within 1/16 inch. If they do not, re-mark before proceeding.

Setting Up Plumb Control

Plumb control means every wythe face is vertically true — not leaning in, out, or twisting along its length. You use two tools together: a 4-foot mason's level for intermediate checks and a plumb bob for absolute vertical reference at corners and leads.

Plumb bob setup: Anchor the plumb bob string to a nail or line pin at the top of the corner. Let the bob hang free — do not let it touch the wall. Wait for the bob to stop swinging before reading. The string represents true vertical; the face of the unit should be a consistent, small distance from that string at every course. Measure the offset at the bottom and top; they must match.

Level checks: After setting each course, hold the 4-ft level vertically against the face of the wall. The bubble must read plumb. Do this at both ends of the course and at the midpoint of any run longer than 4 feet. Use a torpedo level on individual units when the 4-ft level cannot reach.

Laying Out the Dry-Stack Practice Wall

1. Snap a chalk line on your work surface for the face of the wall.

2. Place your corner unit. Hold the plumb bob above it; confirm the face falls on the chalk line.

3. Set the story pole plumb at the corner, "0" mark at the work surface. Clamp or have a partner hold it.

4. Lay units for Course 1, butting the face to the chalk line. Use the story pole to confirm the top of the first course aligns with the C1 mark.

5. Check face plumb with the 4-ft level. Correct any unit that is out before moving up.

6. Repeat course by course through Course 8. Do not skip a plumb check.

7. At the end, photograph the full wall with a ruler held against the story pole at each mark for your documentation log.

Tolerances and Documentation

Industry practice requires:

Log actual versus theoretical height for every course. Circle any deviation greater than 1/8 inch and note the cause. Your instructor will measure and initial the log; all three tolerances must be met to pass.

Safety

Key terms10

Story poleA straight length of wood marked at every course height for a specific unit-and-joint combination, used as a repeatable vertical reference during wall layout.
Course heightThe combined vertical dimension of one masonry unit plus one mortar joint; for standard modular brick this is 3 inches (2-5/8 inch unit + 3/8 inch joint).
Modular brickA brick whose nominal dimensions are sized so that a whole number of courses equals a standard increment; the standard modular brick has a 3-inch nominal course height.
CMU (Concrete Masonry Unit)A hollow or solid block manufactured from Portland cement and aggregate, commonly available in an 8-inch nominal height that sets an 8-3/8-inch course with a standard joint.
Plumb bobA pointed metal weight suspended on a string that uses gravity to establish a true vertical reference line.
PlumbExactly vertical; a wall face or corner is plumb when it aligns with a true vertical reference such as a plumb bob string or a level's vertical vial.
Cumulative errorThe buildup of small individual measurement mistakes into a larger total error; story poles prevent this by providing a single pre-confirmed reference rather than repeated chained measurements.
Dry-stack layoutPlacing masonry units without mortar for the purpose of checking dimensions, spacing, and alignment before final setting; used here as a practice and verification method.
Combination squareA multi-function hand tool with a sliding blade used to measure and scribe exact 90-degree or 45-degree lines; used in story pole fabrication to step off consistent course heights.
ToleranceThe allowable range of variation from a specified dimension; in this lesson, story pole marks must be within 1/16 inch and wall plumb and course heights within 1/8 inch.

Worked examples4

1. Mark a story pole for 8 courses of standard modular brick. What is the cumulative height at Course 5, and what total length of 1×2 do you need for all 8 marks?
  1. Step 1 – Confirm course height: 2-5/8 inch unit + 3/8 inch joint = 3 inches per course.
  2. Step 2 – Calculate cumulative height at Course 5: 5 courses × 3 in/course = 15 inches.
  3. Step 3 – Calculate total marked length for 8 courses: 8 × 3 in = 24 inches.
  4. Step 4 – Select a 1×2 at least 24 inches long; mark "0" at one end, then scribe marks at 3", 6", 9", 12", 15", 18", 21", and 24", labeling each C1 through C8.
Answer: Course 5 mark is at 15 inches; you need a pole with at least 24 inches of usable length.
2. A student measures the actual top of Course 3 on the dry-stack wall and finds it is 9-3/16 inches above the base. The story pole mark for C3 is at 9 inches. Is this within tolerance, and by how much does it deviate?
  1. Step 1 – Find the deviation: 9-3/16 in − 9 in = 3/16 inch.
  2. Step 2 – Convert to a common fraction for comparison: the tolerance is 1/8 inch = 2/16 inch.
  3. Step 3 – Compare: 3/16 inch > 2/16 inch, so the deviation exceeds the 1/8-inch tolerance.
  4. Step 4 – Action required: the student must adjust the units in Courses 1–3 to reduce the accumulated height error before continuing.
Answer: The deviation is 3/16 inch, which exceeds the 1/8-inch (2/16-inch) tolerance; correction is required.
3. You are marking a story pole for 8-inch CMU with a 3/8-inch mortar joint. What is the cumulative height at Course 4?
  1. Step 1 – Confirm course height: 8-inch unit + 3/8-inch joint = 8-3/8 inches per course.
  2. Step 2 – Convert 8-3/8 to a decimal for multiplication: 8.375 inches.
  3. Step 3 – Multiply by 4 courses: 4 × 8.375 = 33.5 inches.
  4. Step 4 – Convert back to fractional inches: 33.5 inches = 33-1/2 inches. Mark C4 at 33-1/2 inches from the base.
Answer: Course 4 mark for 8-inch CMU with a 3/8-inch joint is at 33-1/2 inches (33.5 inches) from the base.
4. A plumb bob check shows the face of the wall is 1/4 inch off plumb over a 4-foot height. The tolerance is 1/8 inch over 4 feet. By how much does the wall exceed tolerance, and what must the student do?
  1. Step 1 – State the measured deviation: 1/4 inch = 2/8 inch over 4 feet.
  2. Step 2 – State the tolerance: 1/8 inch over 4 feet.
  3. Step 3 – Calculate excess: 2/8 inch − 1/8 inch = 1/8 inch beyond the allowable limit.
  4. Step 4 – Required action: dismantle the out-of-plumb courses, re-establish the plumb line, and relay the units so the face aligns within 1/8 inch of the plumb bob string over the full 4-foot height before documenting.
Answer: The wall is 1/8 inch beyond the 1/8-inch tolerance (total deviation 1/4 inch). The affected courses must be taken down and relaid within tolerance.

The math in this lesson2

Learners compute cumulative brick and CMU course heights for a story pole and compare plumb against 1/8 in per 4 ft.
N-Q.1N-Q.3
Brush up in the math halls at newSchoolWorks.com:
In class: Story pole fabrication: each student selects either standard modular brick (2-5/8 inch with 3/8 inch joint = 3-inch course) or 8-inch CMU (8-inch course) and marks a 1×2 wood pole for a full 8-course section, confirming dimensions against a physical unit and NCCER coursing tables. · Controlled wall layout: using the story pole, a 4-ft mason's level, and a plumb bob, students lay out a dry (no mortar) practice wall course by course, checking face plumb at every course and correcting before the next is set. · Documentation exercise: students photograph the completed practice wall with a ruler held against the story pole at each course, log actual vs. theoretical heights, and identify any deviation greater than 1/8 inch per course.
Materials: 1×2 wood strips, pencils, tape measure, combination square, 4-ft mason's level, torpedo level, plumb bob, chalk line, sample brick or CMU units, layout log sheets, smartphone or camera; NCCER Masonry Level 2 Layout module; safety glasses, work gloves
Check: Story pole dimensioned correctly to ≤ 1/16 inch per mark; dry-stack wall plumb to within 1/8 inch over 4 ft and course heights within 1/8 inch of story pole marks; instructor measures and initials layout log. Pass = all three tolerances met.

Practice check8

Answer each question, then check it. Nothing is recorded; this is your own practice.

NCCER Masonry — Layout and Leveling
1. What is the course height for standard modular brick with a 3/8-inch mortar joint?
NCCER Masonry — Layout and Leveling
2. Why do masons use a story pole rather than measuring each course height independently with a tape measure?
NCCER Masonry — Layout and Leveling
3. When fabricating a story pole, what should a student do FIRST before scribing any marks?
NCCER Masonry — Layout and Leveling
4. A completed story pole for brick shows the C6 mark at 18-1/8 inches instead of 18 inches. What should the student do?
NCCER Masonry — Layout and Leveling
5. During a plumb bob check at a dry-stack wall corner, the string hangs 3/16 inch away from the face at the bottom but 5/16 inch away at the top of an 4-foot section. What does this indicate?
OSHA 10 — Personal Protective Equipment
6. Which personal protective equipment (PPE) is required during story pole fabrication and dry-stack wall layout?
NCCER Masonry — Layout and Leveling
7. A student measures Course 7 on the practice wall and finds it at 21-3/16 inches; the story pole mark is at 21 inches. What is the correct action?
NCCER Masonry — Layout and Leveling
8. What is the primary purpose of waiting for a plumb bob to stop swinging before taking a reading?
Record this lesson on my transcript. Sign in with your key and enrollment email to record lessons (enroll free if you have no key). This page stays open to read and practise.
← Previous lessonProgram planNext lesson →