Prior to any census, the country usually gets demarcated into small geographic units called census enumeration areas, districts or blocks. In most countries, these small geographic units are also used for census dissemination. In cases where they are not used for census release, they are normally used as building blocks for developing output areas or they are aggregated to higher spatial levels in an effort to preserve privacy or confidentiality. Buildings blocks are therefore, of significant importance towards results that could be drawn from either aggregated higher level or from output areas developed using these small geographic areas. This paper aimed at evaluating the effects of different building blocks on the statistical characteristics of output areas generated using the Automated Zone-design Tool (AZTool) computer program. Different spatial layers (such as Enumeration Areas (EAs), Small Area Layers (SALs) and SubPlaces) from the 2001 census data were used as building blocks for the generation of census output areas with AZTool program in both rural and urban areas of South Africa. One way-Analysis of Variance (ANOVA) was also performed to determine statistical significance of the AZTool results. Results showed that the AZTool output areas generated from smaller areas (EAs and SALs) tend to be more homogeneous than the ones generated from larger areas (SubPlaces) when using dwelling type and geotype as homogeneity variables. The output areas from smaller areas also had narrower population distribution and more compact shapes than their counter-parts. In addition, the AZTool optimised output areas from the smaller areas allowed a clear distinction of the scale effects than output areas from larger areas. It was concluded that indeed different building blocks did have an impact on the statistical qualities of the AZTool optimised output areas in both rural and urban settings in South Africa.