Masonry Materials Guide

Masonry Materials
Units
Durgesh C. Rai
Professor
http://www.brick.com
Clay Bricks
Department of Civil Engineering

Indian Institute of Technology Kanpur
Kanpur - 208 016
Classification
Clay Brick units
Clay Bricks
Raw materials
Most Common
Two types of
Clay
Types
Surface clays : sedimentary formation
Shales : Clays subjected to high pressure until they become slate
Fire clay : Deeper sites, refractory like properties
Un-burnt
Burnt
Clay
Chemical composition
Silica & Alumina
CE625A: Masonry Structures/Dr Durgesh Rai/IITK/2015
Iron oxide
Hydrated silicates of alumina
Miscellaneous impurities (e.g., Ca, Mg, Na, Ti, K)
Metallic oxide gives color to fired product
Clay Brick units

units
Clay Brick units

units
Significant physical properties of clays

Plasticity
Fusibility
Tensile strength
Shrinkage
Winning and storage of raw materials

Usually mined from open pits
Preparation
Grinding
Sieving
Pug mills
CE625-Masonry structures/Dr Durgesh Rai/IITK/2012
Manufacturing Bricks
Forming
Tempering
To produce homogeneous , plastic mass ready for moulding
Mixing water to clays in pug mills
Clay Brick units

units
Clay Brick units

units
Drying
Forming
Control temperature & humidity

To avoid excessive cracking
Three processes
Firing
Stiff mud process
40-150 hours
12-15% water by weight

Pugging and De-airing gives increased strength
Forms clay strip through extruder-wire cutter
Clays soften slowly and melt and fuse gradually when subjected to rising
temeperatures
This fusibility of clay makes it hars, solid and of low absorbing capacity
Fusion stages
Soft mud process
Incipient stage: Soft particle stick together

Vitrification stage: Clays form solid, non-absorbent mass (875-1300 C)
Viscous stage: Clay mass breaks down and tends to become molten (should avoid
this stage)
20-30% of water by weight

Cast in moulds sand struck
Lubricated with water
Cooling
Dry press process
Important stage
48-72 hours
Rapid cooling will cause cracking
7-10% of water by weight

Steel moulds under pressure of 3.4-10 MPa
7
Clay Brick units

units
Clay Brick units

units
Brick forming machine
Firing in Clamps/Scoves
10
Clay Brick units

units
Clay Brick units

units
Bulls Trench Kiln
Hoffmans Kiln
Continuous
11
12
Engineering Properties
Properties
Compressive strength
Absorption
Properties of clays and methods of manufacture
Related to degree of burning of clay particles, fusing

temperatures and porosity
Stiff mud process produces bricks of higher compressive

strength
Durability
Degree of firing
For given clay and method of manufacture, higher firing
temperature produces bricks of higher strength and lower
absorption
Incipient fusion
Partial Vitrification
Flexural Strength
Thermal Conductivity
Acoustics
Fire Resistance
13
Factors affecting are same as those for compressive strength
Elastic Modulus
Split Tensile Strength
14
Physical Properties
Water Absorption
Colour
Total Water Absorption =
Iron oxide content controls, but depends on
Weight of water absorbed after 24 hrs in cold water

Total dry weight
Oxidizing (red) or reducing (purple) environs
Texture
(a) Saturation Coefficient C/B Ratio =
Smooth or sand finished
Weight of water absorbed after 24 hrs in cold water .

Total absorption after 5hr boiling + 24 hr in cold water
Form and size variation

Air 2-8%
Fire 2.5-10%
C/B ratio is measure of freeze-thaw durability and should not be

greater than 0.78.
Dimensional stability
Primary pores filled by

cold water
15
Secondary pores filled

by boiling water
16
Water Absorption
Water Absorption
Absorption
(b) Initial Rate of Absorption
Water Absorption and Initial Rate of Absorption

- Gives information about quality of bricks
IRA = (W1-W)/Anet
W1=Weight of brick after 1 min in 1/8 (3 mm) water
W= Dry weight of the brick
WA: Water Absorption capacity of the brick material

IRA: Suction of water from mortar due to capillary
action in bricks (per minute, per unit area, brick
immersed in about 3 mm deep water)
WA
IRA
17
IRA < 30g/min/30in2

Usually IRA is 5.0-40.0g/min/30in2 (0.25-2.05 kg/min/m2)
IRA < 0.25 kg/min/m2
Bricks may float on mortar, if the brick is damp
Low Absorption-Low suction Units
fb
IRA > 1.5 kg/min/m2

Highly absorptive
Poor bond if dry thin layer of mortar is kept next to it
Should be wet before (3-24 hrs),
but surface is dry when laid with mortar
18
Water Absorption
Absorption
(b) Initial Rate of Absorption
Compressive Strength
High IRA is undesirable because of
Depends on
Rapid drying of mortar

Poor bond strength between brick and mortar
Poor non-structural performance
due to water penetration into masonry
Soaking of units is desired if IRA > 1.5 kg/min/m2
Clays
Type of manufacturing process
Degree of burning
Tested Flat-wise (ASTM C67)

fb = P/Anet
If Anet>Agross (75%), then use Anet = Agross
Since core will add strength because of
19
20
Uniform drying and Shrinkage

Bond action between mortar and brick
Properties
Properties
Modulus of Elasticity
North American bricks
Eb=1400-5000 ksi (9.8-35.0 GPa)
3-30ksi (21-210 MPa)

Nominal Strength (8-15ksi) (56-105 MPa)
Modulus of Rupture
Indian Bricks
fr =1.5 Pl/bt2
> 3.5 MPa

10-20 MPa common for bricks in North India
b
t
Sahlin: fr /fb varies ~0.1-0.32
Coefficient of Thermal Expansion

0.0045-0.0072 mm/m/C
(Fire clays Shale Surface clays)
21
22
Tests on Bricks
Tensile Strength of Brick Units
Flowchart
Split tensile strength, ft (ASTM C 1006-07)
Flat position
On edge position
P
ft
2P
LH
H
Alignment Jig
Dry Bricks in oven for 24 hours

Weigh dry bricks (determine density)
Run IRA
Dry Bricks
Run Modulus of Rupture Test
Run Absorption Test
Soak in cold water for 24 hours
Split tensile failure
Run Saturation Coefficient Test (optional)

Soak half-bricks in boiling water 5 hours
Run flat-wise Compressive Test (Cap and crush)

23
Flat Position
On Edge Position
24
IS 1077: Bricks
IS 1077: Bricks
Class of bricks
Dimension of bricks
Based on compressive strength
Common brick size

Approx. 23511070 mm (94.52.75 in.)
25
26
IS 1077: Bricks
Compressive Behaviour Clay Bricks
Water Absorption
Compressive Stress-Strain Curves of Brick Units

-Research at IIT Kanpur (Kaushik et al 2007)
Four brick manufacturers:
M: MBF
B: Bajrang
O: Onkar
S: Sarang
Average Dimensions:
Length 230 mm
Width 110 mm
Height 75 mm
27
28

30
Compressive Stress, MPa
Test Setup
O
25
10
5
0
0.000
30
12000
M bricks
10000
Eb 150fb to 500fb
Eb 500 f b
Eb 300 f b
C r =0.39
O bricks
6000
S bricks
Eb 150 f b
4000
2000
0.006
Strain
0.008
317 f b
300 f b
0.010
0.012
Brick type
fb (MPa)
Failure strain
Eb (MPa)
M (10 specimens)
17.7 [0.23]
0.0072 [0.18]
5300 [0.15]
B (10 specimens)
16.1 [0.08]
0.0060 [0.19]
5030 [0.34]
O (10 specimens)
28.9 [0.23]
0.0070 [0.39]
7516 [0.26]
S (10 specimens)
20.6 [0.17]
0.0057 [0.28]
6534 [0.10]
Avg (40 specimens)
20.8 [0.33]
0.0065 [0.34]
6095 [0.29]
[] COV
40 brick specimens
10
20
30
Brick compressive strength, MPa
30
20
10
C r = - 0.77
1
2
IRA, kg/m2/min
C r = - 0.24
10
12
14
WA, %
16
IRA and fb are more closely correlated

Too low IRA, bricks may float on mortar
Too high IRA, rapid suction of water in mortar by bricks
Poor Brick-Mortar Bond
40
Cr Correlation Coefficient (Poor Cr for Eb 300fb )

31
40
0
0
0.004
312 f b
260 f b
IRA vs. WA
B bricks
8000
0.002
300 f b
Comp. stress, MPa
Brick elastic modulus, MPa
Variation of fb with Eb
15
Eb - slope between
0.05fb - 0.33fb
Average
M Eb
M
B Eb
O Eb
S Eb
Eb
20
Typical crushing failure

29
IRA test is not mandatory as per IS:3495 (1992)

32
Fly Ash Bricks

Advantages
Higher cold crushing strength (10-15 MPa)
Low water absorption (13-15%)
Reduced efflorescence
Smooth and uniform size
Requires less quantity of
cement mortar & no plaster
Lower bulk density (1600 kg/m3)
Reduces dead weight
on load bearing walls
Saves transportation cost
Fly Ash Bricks

33
34
Methods of Manufacturing
Primary Ingredients
Moulding
Fly ash (Grade 1 or 2 of IS 3812)

Sand
Lime (Hydraulic Class C of IS 712)
Chemical accelerators, small quantity such as
Gypsum, cement, etc.
Fly ash is a non-plastic material

Raw mix is subjected to a pressure of ~25 MPa
in a suitable hydraulic press
Mixing
In the first stage, only dry mixing is done
About 8- 10% water, 0.2% (by weight) chemical
accelerator is added in the second stage mixing.
This admixture is further subjected to thorough
mixing in the third stage.
35
36
Double acting brick press (Cybertek

Engineering, Faridabad)
Brick Press (CBRI, Roorkee)
Specifications
IS 12894-2002
Drying
Green bricks exposed to natural drying
for about 48-60 hours
Dimensions same as clay bricks

Depending upon weather conditions
Steam Curing
Semi- dried bricks cured in Autoclaves
(steam chamber) at a desired pressure & temperature
Steam cured finished bricks stacked in open
They gain further strength
37
38
Specifications
IS 12894-2002
Water Absorption
Efflorescence
AAC Blocks
39
40
10
Concrete Masonry Units
Autoclaved Aerated Concrete
Manufacturing
Light-weight cementitious material with closed cellular structure
Developed by Swedish architect Johan Axel Eriksson in 1900s

AAC is a mixture of cement, sand, lime, gypsum and
aluminium powder which is steam cured
Aluminum powder reacts with calcium hydroxide and water
to form hydrogen, which increases the volume by two to three
times.
At the end of the foaming process, the hydrogen escapes into
the atmosphere and is replaced by air.
Finally, the blocks are cured in an autoclave, producing a
final material, with about one-fifth to one-third the density of
structural concrete.
Can be cut and nailed like wood and good thermal insulation
and fire resistance of concrete
Low strength and stiffness compared to conventional masonry

Easily cut into any shape with hand tools
Good fire, thermal and acoustic resistance
AAC Blocks
(Fortune EkoTech)
41
Cellular structure of AAC

(Tanner, 2003)
DEPARTMENT OF CIVIL ENGINEERING, IIT KANPUR

Manufacturing
41
42
Comparison of Conventional Units and

AAC Blocks
Tests conducted at IIT Kanpur (2012)

Properties
Density (kg/m3)
Water Absorption (%)
Clay
Fly-Ash
AAC
block
1774.0
1740.0
1520.0
1600.0
709
13.4
15.0
24.4
25.4
321.7
0.82
0.91
0.88
0.58
IRA (kg/m2/min)
2.7
4.4
4.4
1.6
2.7
Compressive Strength (MPa)
21.9
5.4
5.3
9.1
2.4
Flat position
1.0
0.3
0.4
0.4
On edge
1.7
0.5
0.5
0.7
Saturation Coefficient
Tensile Strength
(MPa)
0.4
43
11

Dimensions BHL
Specified dimension 3/8 < Nominal dimension
Actual dimension within 1/8 (3mm) of
Specified dimension
Example
Nominal Dimension: 200200400 mm
Specified Dimension: 190190390 mm
Tapered holes, top-thicker web for better mortar placement

and ease of lifting out of moulds
B
Concrete Blocks
H
L
46
Physical Requirements
Requirements
Concrete Blocks
47
No. 47
48
12
IS 2185 (Part 1):2005
49
IS 2185 (Part 1):2005
50
RAW MATERIALS
METHODS OF MANUFACTURING
Constituents
Separate and weigh aggregates
Portland Cement
Pozzolanas
Aggregate stored by density and gradation

Weighed
Transported
Reduce expansive characteristic

Add surface resistance
Other Admixtures
Mixing
Air entrainment, pigments, water repellants,
Cement + Aggregate + water + pigments+

admixtures to create damp (but not wet) mix
Aggregates
Normal Weight
>125 pcf (2000 kg/m3)
Light Weight
<105 pcf (1680 kg/m3)
51
52
13
MANUFACTURING
MANUFACTURING
Moulding
Curing
Feed to mould
Consolidated by vibration (feed time)
Press mix into mould
Second vibration cycle consolidates mix (finish time)
Done under saturated conditions

Elevate temperature for accelerated hydration
Store outside for continued curing
Ejection
Come out in a set of 3 supported on steel pallets
Bottom of mold cavities
Put in kiln for 6-8 hrs

53
54
MANUFACTURING
Absorption
Production Plant
Weight changes after 24hr immersion in cold water

200350 kg/m3
Total Linear shrinkage

Up to 0.065% for Type I Units
Moisture Content
25-45%
14-42 MPa (lower values in India!)
Tensile Strength
1.75-3.50 MPa
Deformational Properties
Em=750 fm ; Gm=0.4Em;
55
http://www.besser.com
m=0.28
56
14
Requirements
IS 2185 (Part 1) :2005 Concrete Blocks
IS Concrete Blocks
Type
Type
Hollow load
bearing unit
(Open & closed
cavities)
Grade
Minimum
Compressive
Strength (MPa)
Minimum
Compressive
Strength of
individual
units (MPa)
3.5
2.8
4.5
3.6
A(5.5)
5.5
4.4
A(7.0)
7.0
5.6
A(8.5)
8.5
7.0
A(10.0)
10.0
8.0
A(12.5)
12.5
10.0
A(15.0)
15.0
12.0
A(3.5)
A(4.5)
Density of
Block
(kg/m3)
Not less than

1500
57
Grade
Hollow non-load
bearing unit
(open & closed
cavity)
B (3.5)
Solid Load
bearing units
C(5.0)
B(5.0)
C(4.0)
Minimum
Compressive
Strength (MPa)
Minimum
Compressive
Strength of
individual
units (MPa)
Less than
1500 but not
less than
1100
3.5
2.8
5.0
4.0
Not less than

1800
5.0
4.0
4.0
3.2
Density of
Block
(kg/m3)
58
Requirements
Requirements
Concrete Blocks Machines
Concrete Blocks Machines
59
Besser Machine in India in 1950s

Sindhu Resettlement Corporation
Gandhidham city
2001 Bhuj Earthquake
60
15

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Masonry Materials

Department of Civil Engineering

Clay Brick units

CE625A: Masonry Structures/Dr Durgesh Rai/IITK/2015

Clay Brick units

Clay Brick units

Significant physical properties of clays

Winning and storage of raw materials

Clay Brick units

Clay Brick units

Control temperature & humidity

Stiff mud process

12-15% water by weight

Soft mud process

Incipient stage: Soft particle stick together

20-30% of water by weight

Dry press process

7-10% of water by weight

CE625A: Masonry Structures/Dr Durgesh Rai/IITK/2015

Clay Brick units

Clay Brick units

Brick forming machine

Clay Brick units

Clay Brick units

Bulls Trench Kiln

CE625A: Masonry Structures/Dr Durgesh Rai/IITK/2015

Properties of clays and methods of manufacture

Related to degree of burning of clay particles, fusing

Stiff mud process produces bricks of higher compressive

Factors affecting are same as those for compressive strength

Total Water Absorption =

Iron oxide content controls, but depends on

Weight of water absorbed after 24 hrs in cold water

Oxidizing (red) or reducing (purple) environs

Smooth or sand finished

Weight of water absorbed after 24 hrs in cold water .

Form and size variation

C/B ratio is measure of freeze-thaw durability and should not be

Primary pores filled by

CE625A: Masonry Structures/Dr Durgesh Rai/IITK/2015

Secondary pores filled

(b) Initial Rate of Absorption

Water Absorption and Initial Rate of Absorption

WA: Water Absorption capacity of the brick material

IRA < 30g/min/30in2

IRA > 1.5 kg/min/m2

(b) Initial Rate of Absorption

High IRA is undesirable because of

Rapid drying of mortar

Tested Flat-wise (ASTM C67)

CE625A: Masonry Structures/Dr Durgesh Rai/IITK/2015

Uniform drying and Shrinkage

North American bricks

Eb=1400-5000 ksi (9.8-35.0 GPa)

3-30ksi (21-210 MPa)

> 3.5 MPa

Sahlin: fr /fb varies ~0.1-0.32

Coefficient of Thermal Expansion

Tensile Strength of Brick Units

Split tensile strength, ft (ASTM C 1006-07)

Dry Bricks in oven for 24 hours

Split tensile failure