BRICKWORK TESTING ON LOCALLY PRODUCED CEMENT SAND BRICK-LABORATORY TESTING
SITI FAUZIAH BT SAMSUDIN
Universiti Malaysia Sarawak 2000
TA S623 679 2000
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UNIVERSITI MALAYSIA SARAWAK
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BRICKWORK TESTING ON LOCALLY PRODUCED CEMENT SAND BRICK - LABORATORY TESTING
SITI FAUZIAH BT SAMSUDIN
Universiti Malaysia Sarawak
2000
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Maklumat Abttem
UNIVERSm MAL YSlA S AWAK
BRICKWORK TESTING ON LOCALLY PRODUCED CEMENT SAND BRICK
LABORATORY TESTING
Written by
SITI FAUZIAH BT SAMSUDIN
The project report submitted in partial fulfillment for degree of Bachelor of Engineering (Hons) Civil Engineering in Universiti
Malaysia Sarawak
FACULTY OF ENGINEERING UNIVERSITI MALAYSIA SARAWAK
Mac 2000
Uojversjti Malaysja Sarawak
Kota Samarahan
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BORANG PENYERAHAN TESIS
Judu1 : BRICKWORK TESTING ON LOCALLY PRODUCE BRICK ( Laboratory Testing)
SESI P GA.JlAN: 1997·2000
Saya SIn FAUZIAH BT SA~SUDIN
(RURUF SESAR)
mengaku membenarkan lesis ini disimpan di Pusal Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
1. Hakmilik kcrtas projek adalah di bawah nama pcnuhs meloinkan penulisan sebagai projek bcrsama don dibiayoi oleh UNlMAS, hnkmiliknya ada/ah kepunytutn UNU"fAS.
2. Naskhah saunan di dalam bcntuk kcrt.as alau mwo hanya botch dibual dcngan kcbcnaran bcrtulis daripada penuJis.
3. Pusat Khidmat Maklumat Akademik, UNlMAS dibenarkan membuat salinan untuk pengajian mercka. 4. Kerlas projek hooya boleh diterbitkan dengon kcbenaran penulis. Bayaran royalti adalah mcngikut kadar
yang diperselujui kelak. '
5. .... Saya membenarkanltidak memben8l'kan Perpustakaan membual salinan kertas projek ini sebagai bahan pcttukaran di amaro institusi pengajian tinggi.
6. .. Si\a tandakan (./ )
[:=t SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang tennaktub di dalam AKTA RAHSIA RASMI 1972).
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasil badan di mana penyelidikan dijalankan).
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TERHAD[ZJ TlDAK TERHAD
~ANGAN
PENULlS)Alamat tctap: 19, Jla Sri Mersing 34, Tmn. Sri Andalas.
41200 Klang, Selangor.
(03 -3236145)
Tarikh: II Mei 2000
Pn. AZIDA HJ. RASHJDI (Nama Penyelia)
Tarikh:
CATATAN Potong yang tidak berkenaan.
JIla Kertas Pnliek inl SULlT ata.. TERHAD, sila la..pirbn ~urat daripadJI pihak berkuasal orp.ssi berkenaan denrJln menyertakan slObli tempoh kertal projek. Ini perlu dikelaskan
sebago SULIT atau TERHAD.
1'k..I2000
FORM OF ACCEPTANCE
This thesis entitled "Brickwork Testing on Locally Produced Cement Sand Brick - Laboratory Tetsing" was written by Siti Fauziah Bt Samsudin as a partial fulfillment for degree of Bachelor of Engineering (Hons) Civil Engineering in, UNlMAS is accepted and certified by:
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. . . .. .. ... .
Date
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Teri~timewa buat ayahanda dan bonda tersayang...
III
J
I PENGHARGAAN
Assalamualaikum wbtr dan salam sejahtera....
AlhamduWlah, bersyukur ke hadrat Allah Subhanahu Wata'ala kerana dengan kekuatan yang telah diberikan olehNya dapat saya menyiapkan projek ilmiah tahun akhir ini dengan jayanya serta dapat disiapkan pada masa yang ditetapkan.
Di kesempatan ini juga saya mgm mengucapkan jutaan terima kasih kepada ayahanda Samsudin Bin Abdul Samat dan bonda LatifIah Bt Latif!, atas segala dorongan dan pengorbanan kalian sepanjang pengajian anakanda di UNIMAS.
Terima kasih juga buat ahli keluarga dan sahabat handai yang sentiasa menyokong dari belakang. Semoga pengorbanan kalian mendapat balasan daripada Allah SWT. InsyaAllah.
Jutaan terima kasih juga diucapkan buat pensyarah penasihat, Pn. Azida Hj.
Rashidi yang banyak membantu serta memberi bimbingan dan tunjuk ajar selama ini khususnya bagi menyiapkan tesis ini. Segala tunjuk ajar akan dikenang hingga akhir hayat dan restuilah ilmu yang telah diberikan. Berbanyak terima kasih juga diucapkan buat pensyarah-pensyarah serta kakitangan fakulti atas segala bantuan dan sokong·an yang diberikan semasa proses menyiapkan kertas kerja ini. Akhir sekali buat rakan sepejuangan, AfIendi Deris yang telah banyak membantu menyiapkan sampel -sampel ujikaji serta berkongsi maklumat bagi menyelesaikan projek ini. Terima kasih atas segalanya.
Wassalam.
(Siti Fauziah Bt Samsudin)
IV
CONTENT
Form of Acceptance III
Dedikasi iv
Penghargaan v
Contents vi
List of Table x
List of Figure xi
List of Graph xii
Abstrak xiii
Abstract xiv
CHAPTER 1: INTRODUCTION
1.1 Introduction 1-1
1.2 Types of Material for Masonry Construction I-I
1.3 Types of Bricks 1-2
1.3.1 Clay Brick 1-2
1.3.2 Calcium Silicate Brick 1-3
1.3.3 Concrete Brick 1-3
1.4 Locally Produced Brick 1-4
1.5 Research Significance 1-5
1.6 Objective of Thesis 1-6
1.7 Limitations 1-6
1.8 Conclusion 1-7
v
CHAPTER 2: LITERATURE REVIEW
2.1 Introduction 2-8
2.2 Constituent Materials 2-8
2.3 Manufacturing of Concrete Masonry Units 2-9
2.3.1 Aggregate Concrete Block 2-10
2.3.2 Aereted Concrete Block 2-11
2.4 Form and Size 2-12
2.5 Properties 2-13
2.5.1 Density 2-13
2.5.2 Strength 2-14
2.5.3 Modulus of Elasticity 2-14
2.5.4 Dimensional Changes 2-15
2.5.5 Durability 2-15
2.5.6 Efflorescence 2-15
2.5.7 Fire Resistance 2-16
2.5.8 Thermal Conductivity 2-16
2.6 Types of Bond 2-16
2.6.1 Structural Bond ~. 2-17
2.6.2 Pattern Bond 2-18
2.6.3 Mortar Joints 2-19
2.7 Conclusion 2-21
CHAPTER 3: METHODOLOGY
3.1 Introduction 3-22
3.2 Assumption I Precaution 3-22
VI
I",
3.3
3.4
3.5
3.6
3.7
3.8
Measurement of Dimension 3.3.1 Objective
3.3.2 Methods
Determination of Compressive Strength, fb (Single unit) 3.4.1
3.4.2 3.4.3 3.4.4
Objective Appratus
Preparation of Specimen Method
Prism Test 3.5.1 Objective 3.5.2 Apparatus 3.5.3 Methods
Flexural Stength Test 3.6.1 Objective
3.6.2 Preparation of Specimens 3.6.3 Format ofWallette
3.6.4 Test Procedure Mortar Test
",
3.7.1 Objective 3.7.2 Methods Conclusion
CHAPTER 4: RESULT
4.1 Introduction
4.2 Measurement of Dimensional
3-23 3-23 3-23 3-23 3-23 3-23 3-25 3-25 3-25 3-25 3-27 3-27 3-29 3-29 3-29 3-30 3-30 3-31 3-31 3-31 3-31
4-32 4-32
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II
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4.3 Compressive Strength of Single Brick 4-32
4.3 Prism Test 4-36
4.4 Flexural Test 4-42
4.5 Mortar Test 4-43
4.6 Conclusion 4-43
CHAPTER 5: ANALISIS AND DISCUSSION
5.1 Introduction 5-51
5.2 Dimension Test 5-51
5.3 Compressive Strength of Single Brick 5-52
5.4 Prism Test 5-54
5.5 F1exural Test 5-56
5.6 Mortar Test 5-57
5.7 Experimental Error 5-59
5.8 Conclusion 5-59
CHAPTER 6: CONCLUSION AND RECOMMENDATION
~.
6.1 Conclusion 6-60
6.2 Recommendation 6-61
REFERENCES R-63
APPENDIX A-64
Figure A.1 - Running bond specimen A-65
VIII
Figure A2 - Stack bond specimen A-65
Figure A 3 - Mortar curing A-66
Figure A4 - Mortar in mould size 100 mm3 A-66
Figure A5 - Wayer mesh layer A-67
Figure A 6 - Wallette covering A-67
Figure A 7 - The making of wallette for flexural test A-68 Figure A8 - Mortar mix with proportion 1: 2: 4 A-68
(Water: Cement: Sand)
Figure A9 - Construction work of prism hit 2.3 A-69 Figure Al0 - Construction work of prism hit 1.5 A-69 Figure All - Method of layering brick to casting a wallette A-69 Figure A12 - Placement of sample for prism test A-70
Figure A13 - Cutter brick machine A-70
Figure A.14 (A) - The placement of sample for flexural test A-71 Figure A14 (B) - The placement of sample for flexural test A-71
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IX
LIST OF TABLE
Table Page
1 Measurement of Dimension 4-33
2 Compressive Strength of Brick (Single Unit) 4-34 3 Determination of Characteristic Compressive Strength, 4-37
fk (Prism Test)
3.1 Types of Wallette 3-29
4 Flexural Strength Test 4-46
5 (a) Mortar Test (Prism Trial Cube) 4-48
5 (b) Mortar Test (Flexural Trial Cube) 4-48
5 (c) Mortar Test (Flexural Specimen S 1) 4~49
5 (d) Mortar Test (Flexural Specimens) 4-49
5 (e) Mortar Test (Prism Specimen) 4-50
5 (f) Mortar Test (Prism Specimen) 4-50
x
II [I
Figure 1.1
2.1 2.2 2.3 2.4 2.5 2.6 3.1 3.2 3.3 3.4(a) 3.4(b) 3.5 4.1 4.2 4.3 5.1
LIST OF FIGURE
Page
1-4 Constituent material for concrete masonry unit 2-9
Form and size 2-2
English bond 2-18
Flemish bond 2-18
Types of bond 2-19
Cross-section of typical mortar joints used in brickwork 2-20
Method of checking dimension 3-24
Compresive Machine 3-26
Brick in compressive machine 3-26
Prism with hit 1.5 3-28
Prism with hit 2.3 3-28
The placement of point loading 3-30
Typical shape of concrete masonry unit
~..
Mode of prisms failure 4-41
Mode of flexurals failure 4-44
Mode of mortar cube failure 4-47
Slenderness ratio two through five 5-56
[ XI
,..
LIST OF GRAPH
I' Graph Page
Graph 1 Graph of compressive strength vs number of bricks 5-53
xii
ABSTRAK
Dalam projek ini, satu kajian dibuat terhadap kekuatan bata "cement sand brick" iaitu bata yang terdiri daripada campuran simen dan pasir, untuk menentukan kesesuaiannya dalam pembinaan load bearing.
Bagi memenuhi keperluan tersebut, kajian terhadap bata yang diperolehi daripada Paragon Concrete Sdn. Bhd., J1n Batu Kawa, Kuching, Sarawak dilakukan. Beberapa ujikaji dijalankan bagi menggumpul data kekuatan bata seperti pengukuran dimensi bata, ujian kekuatan bagi seunit bata, ujian kekuatan bagi prism serta ujian kekekuatan bagi panel. Semua ujikaji yang dinyatakan diatas adalah mengikut spesifikasi BS 6073: Partl dan BS 5628: Part l. Turut serta ialah spesifikasi dari ASTM dan BIA bagi tujuan perbandingan kaedah dan hasil ujikaji. Selain daripada itu, ujian terhadap kekuatan mortar juga dilaksanakan untuk menentukan pengaruhnya dalam kekuatan prism dan panel.
Hasil daripada semua keputusan yang diperolehi, satu kesimpulan terhadap mutu kekuatan "cement sand brick" akan diutarakan dengan memberi penekanan kepada kesan keputusan ujikaji serta cadangan bagi memperbaiki mutu ujikaji.
xiii
I
,.... ,.
ABSTRACT
This thesis is going to examine the strength of cement sand brick that is generally constituent of cement and sand. From this research, its suitability for use in the load bearing construction will be tested.
To full fill this requirement, the bricks obtained from Paragon Concrete Sdn. Bhd., JIn Batu Kawa, Kuching, Sarawak were analysed. The series of experiments implemented were the dimension test, compressive strength of single
unit, compressive strength of prism and compressive strength of wallette. These experimental work are correspond to BS 6073: Part 1 and BS 5628: Part 1. Other specifications, which were used, were the ASTM and BIA for method and result comparison. The mortar test was done to determine the influence of mortar in the prism and wallette strength.
From the results obtained, it can be concluded that the quality of cement sand brick can be used for this construction. Last but not least, recommendations to improve the tests are included.
XIV
CHAPTER 1 INTRODUCTION
1.1 Introduction
Many materials have been used . for the construction of masonry, those locally available being most convenient. Therefore, this chapter presents the discussions on the general types of material for masonry construction, types of brick, and the locally produced bricks. The research significance and the objective of this thesis are also explained.
1.2 Types of Material for Masonry Construction
Masonry consists generally of a solid mass produced by bonding the separate units. The traditional bonding material is the mortar. The units include a range of materials and the common ones being the following:
• Stone - these may be esSentially natural form (called rubble or fieldstone) or may be cut to specified shape.
• Brick - these vary from unfired, dried mud (adobe) to fired clay (kiln baked) products. Form, color, and structural properties vary considerably.
• Concrete Blocks (CMUs) - (called concrete masonry units), these are produced from a range of types of material in a large number of form variations.
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• Clay Tile Blocks - used widely in the past, these are hollow units similar to concrete blocks in form. They were used for many of the functions now performed by concrete blocks.
• Gypsum Blocks - these are precast units of gypsum concrete, used mostly for nonstructural partitions.
The potential structural character of masonry depends greatly on the material and form of the units. From the material point of view, the high-fired clay products (brick and tile) are the strongest, producing a very strong construction
with proper mortar, a good arrangement of the units, and good construction craft and work in general. This is particularly important if the general class of the masonry construction is the traditional, unreinforced variety. Although Borne joint reinforcing is typical in all structural masonry these days, the term reinforced masonry is reserved for a class of construction in which major vertical and horizontal reinforcing is used, quite analogous to reinforced concrete construction
1.3 Types of Brick
In general, bricks are divided into three categories, which are Clay Bricks, Calcium Silicate Bricks and Concrete Bricks
1.3.1 Clay bricks
Types of clay bricks are listed as follow:
• Common Bricks • Engineering Bricks
• Facing Bricks • Special Shapes
• Load Bearing Bricks
1·2
These bricks are made from the clay or shale, which can be obtained from the earth digging activity. Some bricks can come under more than one of the classifications common, facing, load bearing and engineering. For example, engineering bricks can be used as facing and a number of bricks manufactured as facing under modem conditions can easily reach engineering brick standards
ofstrength and water absorption. Equally, common brick can be used as facing or for load bearing purposes.
1.S.2 Calcium Silicate Bricks
BS 187: Part 2, Metric: 1970 "Calcium Silicate (Sand - Lime) Bricks" is the requirement standard for this kind of brick's. Commonly, these are made from
finely graded sand mixed with lime (5-10 %), pressed to shape and then autoclaved at about 1800c under steam pressure.
The basic materials being bland in color, lend themselves to a range of color is available. Also a range of texture is available. The result is that it is not always easy to distinguish calcium - silicate brickwork from clay brickwork when viewing from a distance.
I.S.S Concrete Brick
Concrete bricks are normally made by compacting the concrete under high pressure into a mould. The pressure employed is such that a high initial strength is achieved enabling the brick to be immediately removed, by extrusion from the mould. The brick is then transported to the curing room on a pallet or conveyor. The brick making machine is therefore operated cyclically and at very high rates .A very high of output is achieved.
1-3
Typical shapes of concrete block are illustrated in figure 1.1
The term concrete masonry unit (eMU) refers to molded concrete units used in construction to build load-bearing and non load-bearing walls. The units are cored or solid and manufactured off site. The raw materials for concrete masonry units are the Portland cement, water, aggregates and in some cases admixtures, which may include coloring agents, air-entraining materials, water repellents and other additives.
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1.4 Locally Produced Bricks
In Sarawak, the locally produced bricks are only the Common clay bricks (Red Brick), Cement Sand Brick and Hollow Concrete Blocks for concrete masonry units. These types of bricks are suitable for housing construction as an
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acoustical material as well as for construction of fire-rated wall system. It also provides a good visual characteristic. Other types of brick are such as Behaton Pave, Grass Pave and Brick Pave, which are used for surfacing pavements for vehicles and pedestrians.
1.5 Research Significance
The significant of this research is to verify the certain design value in load bearing masonry construction. It has been known that load bearing brickwork is a method of construction where the brick walls are used to support all structural load imposed by the roof, upper walls and floor slabs, and lateral loads such as
wind and soil pressure. The brick walls are designed taking into account the strength and types of bricks to be used which can be clay bricks or cement sand
bricks. The factor of safety adopted in the design has to exceed the minimum factor of safety stipulated in the British Standard BS 5628. Therefore, if a rational design approach for masonry is employed, it is essentia~ to establish allowable design stress early in the design process.
Present design standard requ.~ments provide two methods to establish these values. Under these requirements, the ultimate compressive strength (fm) may be determined by prism test or an approximation based upon brick strength and
mortar properties. Usually the prism test method is the preferred method as it provides the designer with more exact information; whereas the approximation method, of necessity, provides more conservative values. Allowable design stress
may be determined under the design standard, once an ultimate compressive strength of masonry has been determined.
1-5
However, usually the prism testing method are not to be used to establish design values, rather, they are used by the contractor to verify that the masonry achieves the specified compressive strength, fm. As same as flexural bond strength test, which are not intended for use in establishing design stresses.
This test may be used as quality assurance tests to measure the flexural bond strength between masonry units and mortar.
1.6 Objective of Thesis
The aims of this thesis are to;
a) Find out the suitability of a locally produced Cement Sand Brick, that is corresponding to BS 6073: Part 1, for load bearing wall system. The brick use in this thesis is a product from Paragon Concrete Sdn. Bhd., JIn Batu Kawa, Kuching Sarawak.
b) To determine the compressive strength of bricks and conformance of dimensions base on BS 6073: Part1,
c) To determine the characteristic compressive strength of masonry (fk) and determination of characteristic of flexural strength of masonry.
1.7 Limitations
The experiment in this project is based on the British Standard (BS) 6073: Part 1, BS 5628: Part 1 and Part 2, American Standard Testing Method (ASTM) and Building Code Requirement for Engineered Brick Masonry, Brick Institute of America (BIA Standard). Those standards are use because they are the general
1-6
standards used worldwide. The other past research, example from Jabatan Kerja Raya (JKR) also has been use for comparison purposes.
1.8 Conclusion
As a summary, this chapter has shared some idea about brick for masonry and load bearing construction. It also gives a clear explanation of objective, research significant and limitation in this project. The thesis as an overall, is covered in seven chapters: Chapter One for introduction, Chapter Two for literature review, Chapter Three for methodology, Chapter Four for result, Chapter Five for discussion, Chapter Six for recommendation and The Conclusion. Finally, The Appendix of this thesis.
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