CE-115 Civil Engineering Materials by ENGR M.ABBAS QURESHI

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CE-115 Civil Engineering MaterialsbyENGR
M.ABBAS QURESHI
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BRICKS
Civil Engineering MaterialsCE-115
Presented by Engr. Bilal Iftikhar
April 27, 2010
Department of Civil Engineering Swedish College
of Engineering And Technology, Wah Cantt
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CIVIL ENGINEERING MATERIALS (CE-115)

• INCTRUCTOR Engr.Bilal Iftikhar
• Phone [phone]
• iranabilal_at_yahoo.com
• OFFICE Staff Room
• TEXT BOOK
• Engineering Materials by Surrendra Singh
• Engineering Materials by R. K. Rajput
• REFERENCE BOOK
• Material of Construction by R.C. Smith
• Building Materials by S. K. Duggal
• Materials of Constructions by ZH Syed

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Building Materials

• Building stones
• Bricks and clay products
• Cement concrete
• Timber and wood products
• Metals and alloys
• Paints, varnishes, distempers
• Asphalt, bitumen and tar
• Plastics and fibers
• Glass
• Asbestos, adhesives and abrasives

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Bricks and Clay Products
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Clay Products

• Clay Products
• Bricks
• Tiles
• Fire clays and fire bricks
• Terracotta
• Earthenware
• Clay pipes
• Bricks
• Block of tampered clay or ceramic material molded
  to desired shape and size, sun dried and if
  required burnt to make it more strong, hard and
  durable

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Bricks

• Commonly it is rectangular in shape
• Length twice width of brick thickness of
  mortar
• Height multiple of width of brick
• Usual size available in Pakistan is 8¾ x 4¼ x 2 ¾
  inches to make it 9 x 4.5 x 3 inches with mortar
• Indian Standard size 19 x 9 x 9 cm and 19 x 9 x 4
  cm to make it 20 x 10 x 10 cm and 20 x 10 x 5 cm
  with mortar
• Bricks are most common form of structural clay
  products others being tiles, pipes, terracotta,
  earthenware, stoneware, and porcelain

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Historical Development

• Began as low walls of stones or caked mud
• Sun-dried bricks - With the availability of fire
  became burnt bricks
• Invention of kilns made mass production of bricks
  easy
• Limestone turned into lime mortar replaced mud as
  mortar
• In Mesopotamia, palaces and temples were built of
  stone and sun-dried bricks in 4000 B.C.
• The Egyptians erected their temples and pyramids
  of stones by 3000 B.C.
• By 300 B.C., Greeks perfected their temples of
  limestone and marble
• Romans made the first large-scale use of masonry
  arches and roof vaults in their basilica, baths
  and aqueducts

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Historical Development

• Medieval and Islamic civilizations perfected
  masonry vaulting to a high degree of development
  - Islamic craftsmen built palaces, markets, and
  mosques of bricks and often faced them with
  brightly glazed tiles
• Europeans built fortresses and cathedrals using
  pointed vaults and flying buttresses
• In America and Asia other cultures were building
  with stones
• During industrial revolution, machines were
  developed to quarry and cut stones, mould bricks,
  and speed the transportation of these materials
  to site of building
• Portland cement came into wide use and this
  enabled the construction of masonry building of
  greater strength and durability

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Historical Development

• Late in 19th century tall buildings were built,
  of steel and reinforced concrete (pored into
  simple forms), economically
• Development of hollow concrete forms in 19th
  century averted the extinction of masonry as a
  building material - Cavity wall, developed by the
  British during the earlier part of the 19th
  century also contributed to the survival of
  masonry as a building material
• This facilitated the introduction of thermal
  insulation
• High strength mortars, high-strength masonry
  units, and complex shapes of masonry units
  extended the use of masonry for buildings

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Historical Development

• Through the mid-1800s
• Primary Building Materials
• Late 1800s
• New Products Developed
• Ended Masonrys Dominance
• 20th Century Developments
• Steel Reinforced Masonry
• High Strength Mortars
• High Strength Masonry Units
• Variety of Sizes, Colors, Textures Coatings

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Adobe

• Spanish-American name applied to sun-dried brick
  and to the clay soil from which the brick is made
• Adobe soil is composed of very fine mixture of
  clay, quartz, and other minerals
• Adobe soil has great plasticity when moist, but
  when dry is so coherent that tillage is almost
  impossible
• Soil is used combined with straw, molded and
  baked in sun for 7 to 14 days
• Used in regions of low rainfall and dampness

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Civil Engineering Uses

• Construction of exterior and interior walls,
  partitions and boundary walls
• Construction of piers, abutments
• Construction of footings
• Construction of miscellaneous load bearing
  structures

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Classification of Bricks
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Classification of Bricks

• Sun Dried, Un-burnt or Kacha Bricks
• After molding dried in sun, and are used in the
  construction of temporary structures which are
  not exposed to rains.
• Burnt or Pucca Bricks
• Burnt in an oven called kiln to provide strength
  and durability

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Classification of Burnt Bricks
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Classification of Burnt BricksField Practice

• First Class Bricks
• Thoroughly burnt, deep red, cherry or copper
  color
• Straight edges, square corners, smooth surface
• Free from flaws, cracks, stones and nodules
• Uniform texture ringing sound
• No scratch marks with fingernails
• Water absorption 12-15 of dry weight in 24 hours
• May have only slight efflorescence
• Crushing strength not less than 10.5 N/mm2
• Recommended for pointing, exposed face work,
  flooring and reinforced brick work

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Classification of Burnt BricksField Practice

• Second Class Bricks
• Small cracks and distortions permitted
• Water absorption 16-20 of dry weight allowed
• Crushing strength not less than 7.0 N/mm2
• Recommended for all hidden work and centering of
  RBC
• Third Class Bricks, Pilla Bricks
• Under burnt, Soft and light colored producing
  dull sound
• Water absorption 25 of dry weight
• Recommended for temporary structures
• Fourth Class Bricks, Jhama, Khingar
• Over burnt and badly distorted in shape and size
• Brittle in nature
• Ballast of these bricks used for foundation and
  floors and as road metal

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Classification of Burnt BricksStrength Based

• Classes
• 350 (35 N/mm2) 125 (12.5 N/mm2)
• 300 (30 N/mm2) 100 (10 N/mm2)
• 250 (25 N/mm2) 75 (7.5 N/mm2)
• 200 (20 N/mm2) 50 (5 N/mm2)
• 175 (17.5 N/mm2) 25 (2.5 N/mm2)
• 150 (15 N/mm2)
• Sub Classes
• Subclass A. Tolerance 0.3 in dimensions
• Subclass B. Tolerance 0.8 in dimensions
• Heavy Duty. Compressive strength gt 40 N/mm2

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Classification of Burnt Bricks

• Basis of Usage
• Common Brick. General multi-purpose
• Facing Brick. Good appearance, color, textured,
  durable under severe exposure
• Engineering Bricks. Strong, impermeable, smooth
  and hard
• Basis of Finish
• Sand Faced Brick. Textured surface by sprinkling
  sand inside mold
• Rustic. Mechanically textured finish

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Classification of Burnt Bricks

• Basis of manufacturing method
• Hand Made. Hand molded
• Machine Made. Wire cut, pressed and molded bricks
• Basis of Burning
• Pale Bricks are under burnt
• Body Bricks are well burnt in central portion of
  kiln
• Arch Bricks are over burnt. Also called clinker

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Comparison of Stones and Bricks

• Stone
• Natural material
• Heavier
• High dressing cost
• Costly except in hilly areas
• Less porous, good for hydraulic structures
• Greater strength
• Better heat conductor
• Weather resistant
• Superior quality stone is monumental and
  decorative

• Bricks
• Manufactured from clay
• Lighter
• Moldable to any shape
• Cheaper except in hilly areas
• More porous, needs water proof treatment
• Reasonable for normal loads
• Poor heat conductor
• Needs pointing and plastering
• Architectural effect is achievable

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Ingredients of Good Brick Earth

• Brick earth is formed by the disintegration of
  igneous rocks. Potash feldspars, orthoclase or
  microcline yield clay minerals which decompose to
  yield kaolinite, a silicate of alumina. On
  hydration it gives a clay deposit Al2O3. 2H2O
  called kaolin.
• Alumina or clay 20-30 by weight
• Silica or sand 35-50 by weight
• Silt 20-35 by weight
• Remaining ingredients 1-2 by weight
• Lime (CaO)
• Magnesia (MgO)
• Iron oxides
• Alkalis (Sodium potash, etc)
• Water

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Ingredients of Good Brick Earth

• Silica, Sand Present as free sand or silicate.
  Its presence in clay produces hardness,
  resistance to heat, durability and prevents
  shrinkage and warping.
• Alumina Fine grained mineral compound. Moldable
  plastic when wet, becomes hard, shrinks, warps
  and cracks when dry.
• Lime Acts as binder for brick particles.
  Reduces shrinkage when present in small amount,
  excess causes the brick to melt and lose shape.

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Ingredients of Good Brick Earth

• Magnesia Provides darker yellow color with
  iron. Usually less than 1.
• Iron Oxide Helps fusion of brick and provides
  light yellow to red color to brick. Should not be
  present as iron pyrites

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Ingredients of Good Brick Earth

• Harmful Substances
• Lime in excess or in lumps and pebbles, gravel,
  etc
• Iron Pyrites
• Alkalis in excess
• Organic Matter
• Carbonaceous Materials
• Additives
• Fly Ash silicates help in strength development
• Sandy Loam controls drying of plastic soil
• Rice Husk Ash controls excessive shrinkage
• Basalt Stone Dust modifies shaping, drying
  firing

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Operations in Manufacturing of Bricks

• Preparation of Brick Earth
• Un-soiling
• Digging
• Weathering
• Blending
• Tempering
• Molding of Bricks
• Drying of Bricks
• Burning of Bricks

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Preparation of Brick Earth

• Un-soiling Removal of top 20 cm organic matter
  and freeing from gravel, coarse sand, lime etc
• Digging additives spread, soil excavated,
  puddled, watered and left over for weathering
• Weathering heaps left for one month for
  oxidation and washing away of excessive salts in
  rain
• Blending sandy earth and calcareous earth mixed
  in right proportions with right amount of water
• Tempering kneading of blended soil with feet or
  with a pug mill to improve plasticity and
  homogeneity

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Pug Mill
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Manufacturing of Burnt Bricks

• Molding giving right shape
• Hand molding
• Ground molding. Molded on sand. No frog in bricks
• Table molding. Molded on stock boards with frog
• Machine molding
• Plastic method or Stiff-Mud process. Molded stiff
  clay bar cut by wire into brick size pieces.
  Structural clay products
• Dry Press method. Moist powdered clay fed into
  machine to be molded into bricks. Roof, floor and
  wall tiles
• Drying Removing 7-30 moisture present during
  molding stage. This controls shrinkage, fuel and
  burning time. Natural open air driers in shades

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Brick Molds
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Table Molding
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Plastic Molding
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Strikes
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Extruded Wire Cut
Extruded Smooth
Wood Mold
Extruded Raked
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Method of Drying Bricks
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Manufacturing of Burnt Bricks

• Burning Stages
• Dehydration (400-650 C). Water smoking stage in
  which water from pores driven off
• Oxidation (650-900 C). Carbon eliminated and
  ferrous iron oxidized to ferric form. Sulphur is
  removed
• Vitrification (900-1250 C). Mass converted into
  glass like substance
• Incipient vitrification. Clay just softens to
  adherence
• Complete vitrification. Maximum shrinkage
• Viscous vitrification. Soft molten mass, loss in
  shape, glossy structure on cooling

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Manufacturing of Burnt Bricks

• Clamp or Pazawah Burning
• Alternate layers of bricks and fuel encased in
  mud plaster.
• Fuel consists of grass, cow dung, litter, wood,
  coal dust
• Brick layer consists of four to five courses of
  brick
• 25,000 to 100,000 bricks in three months cycle
• Kiln Burning
• Intermittent kiln. Loaded, fired, cooled and
  unloaded before next loading
• Continuous kiln. Bricks are loaded, fired, dried
  and cooled simultaneously in different chambers.
  Example Bulls trench kiln and Hoffmans kiln

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Clamp or Pazawah
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Intermittent Kiln
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Hoffmans Continuous Kiln
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Bulls Trench Kiln
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Bulls Trench Kiln
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Characteristics of Good Bricks

• Size and shape uniform size, rectangular
  surfaces, parallel sides, sharp straight edges
• Color uniform deep red or cherry
• Texture and compactness uniform texture,
  fractured surface should not show fissures,
  holes, grits or lumps of lime
• Hardness and soundness not scratch able by
  finger nail. Produce metallic ringing sound
• Water absorption should not exceed 20 wt
• Crushing strength not less than 10.5 N/mm2
• Brick earth free from stones, organic matter

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Special Forms of Bricks

1. Round ended brick
2. Cant brick
3. Splay brick
4. Cornice brick
5. Compass brick
6. Bull nosed brick
7. Perforated brick
8. Hollow brick
9. Coping brick
10. Plinth level brick
11. Split brick (Queen closer)
12. Split brick (King closer)

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Specially Shaped Bricks
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Testing of Bricks

• Dimension Test. Sample size 50. 20 pieces
  selected to determine length, width and height
  tolerances.
• Compressive strength Test. Sample prepared from
  smooth, parallel face, brick is soaked 24 hours
  and stored under damp jute bags for 24 hours
  followed by further immersion in water for three
  days. Load applied _at_ 14 N/mm per minute till
  failure. Maximum load at failure divided by
  average area of bed face gives compressive
  strength.

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Testing of Bricks

• Absorption Test.
• 24 hours immersion cold water test.
• Dry bricks oven dried at 105 5 C
• Room temperature cooled bricks weighed W1
• Bricks immersed in water at 27 2 C for 24 hrs
• Soaked bricks weighed W2
• Water absorption in (W2 W1)/W1 x 100
• Five hours boiling water test
• Oven dried bricks weight W1
• Bricks immersed in water and boiled for 5 hours
  and then cooled down at room temperature in 16-19
  hours
• Cooled down weight as W3
• Water absorption in (W3 W1)/W1 x 100

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Testing of Bricks

• Efflorescence Test. Ends of brick kept in 150 mm
  dia porcelain/glass dish containing 25 mm deep
  water at 2030C till all water is absorbed
• Nil imperceptible efflorescence
• Slight deposit covers area lt 10 of exposed area
• Moderate deposit covers exposed area 10 to 50
• Heavy deposit covers exposed area gt 50
• Serious deposits are heavy and powder or flake
  away the surface

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Defects of Bricks

• Over-burning. Burnt beyond complete vitrification
• Under-burning. Burnt less not to cause complete
  vitrification
• Bloating. Spongy swollen mass over the surface
  due to excess carbonaceous matter and sulphur
• Black Core. Due to bituminous matter or carbon
• Efflorescence. Grey of white crystallization of
  alkalis on the surface, due to water absorption
• Chuffs. Deformation due to rainwater falling or
  hot bricks
• Checks or Cracks. Due to lumps of lime getting in
  contact with water
• Spots. Dark sulphur spots due to iron sulphides
• Blisters. Broken blisters due to air entrapped
  during molding
• Laminations. Thin lamina produced due to air
  entrapped in voids of clay

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Brick Masonry

• Brick sides
• Header
• Stretcher
• Brick Bonds
• English
• Brick Masonry Patterns
• Herringbone
• Basket weave
• Flemish

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Basic Brickwork Terminology
Head Joint
Bed Joint
Course - horizontal layer of brick
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Basic Brickwork Terminology
Header - Bonds two wythes together Wythe
vertical layer 1 unit thick
Rowlock - laid on face, end visible
Stretcher - long dimension horizontal face
parallel to the wall
Soldier - Laid on its end, face parallel
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Joint Color that Blends w/ Brick Color
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Concave Joints
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Raked Joints
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Simulated Precast Concrete Lintel (actually a
steel lintel supports the assembly)
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Arch
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Specially Shaped Bricks
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