5.1 Metakaolin Based Geopolymer Brick

68
CHAPTER 5
COMPRESSIVE STRENGTH AND MODULUS OF

ELASTICITY OF MASONRY PRISMS
In this chapter, after many trials, the mix ratio of metakaolin based
geopolymer brick to attain a compressive strength of 5.5 N/mm2 was designed
to be used in masonry construction. Properties of wire cut clay bricks and
metakaolin based geopolymer bricks were tested in accordance with IS 3495
and compared for its suitability in masonry construction. The behaviour of
metakaolin brick masonry prisms and clay brick masonry prisms of different
aspect ratio constructed in 1:3 cement mortar is studied.
5.1 Metakaolin Based Geopolymer Brick
The demand for ordinary clay bricks leads to a search for alternate bricks
to meet the escalating demand of the construction sector. Production of clay
brick involves usage of natural resources in large quantity and there is non-
uniformity in compressive strength of bricks of different regions. In order to
produce bricks of uniform strength, factory production is resorted to using
materials of known strength. Geopolymer bricks require no firing like clay brick
or curing like commercially available flyash and cement bricks. In this study,
different mix ratios with flyash and metakaolin were studied with sand as fine
aggregate in 1:5 and 1:6 ratios. The proportions of various mix ratios of MK
modified GP brick studied is presented in Table 5.1. 50% replacement of flyash
with metakaolin in 1:6 ratio with liquid to solid ratio of 1 was selected to
produce 1000 bricks of size 190×90×90 mm and an average compressive
strength of 5.5 N/mm2.
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Table 5.1 Mix proportion for Metakaolin Geopolymer brick
1:5 by mass in kg 1:6 by mass in kg

MIX
FA MK SAND LIQUID FA MK SAND LIQUID
MK0 0.45 - 2.25 0.45 0.4 - 2.4 0.4
MK25 0.34 0.11 2.25 0.45 0.3 0.1 2.4 0.4
MK50 0.225 0.225 2.25 0.45 0.2 0.2 2.4 0.4
MK75 0.11 0.34 2.25 0.45 0.1 0.3 2.4 0.4
The minimum compressive strength required for the bricks to be used for
the structural purpose is 5.5 N/mm2 according to IS 1905-1987. Metakaolin 1
was chosen for the casting of bricks as it has lower silica and high alumina and
results in the inferior quality of bricks. Two mix ratios of 1:5 and 1:6 by mass
of MK+FA and sand were identified for Metakaolin based geopolymer bricks
and in each mix ratio, the percentage of MK is varied from 0-75, and the
remaining FA was used. Using trial mixes, the average mass of material
required for a mould of 190×90×90 mm was estimated as 3.2 kg. The solid-
liquid ratio was maintained at 1. Eight different mixes were cast and tested.
12M NaOH solution and sodium silicate solution with 3.2 moduli (mass of
Na2O/SiO2=3.2) was used. The ratio between two liquids was maintained as 2.5.
Eight different types of bricks of mix MK0, MK25, M50, M75 with 1:5 and 1:6
ratio of alumina silicate precursor (FA+MK) and sand.190×90×90 mm size and
40 number of bricks were hand moulded using steel moulds. The stacking of
trial GP brick is shown in Figure 5.1
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Figure 5.1 Stacking of Trial Bricks
5.2 Clay Bricks
In this study, locally available clay bricks were used. They were chosen
to be wire cut bricks to have uniform size and to have consistent properties with
average size of the brick as 220 mm×90 mm×70 mm. 1000 bricks were
procured for use and broken bricks were rejected.
5.3 Tests on Bricks
The properties of bricks were tested in accordance with IS 3495 (1-4)

1992. The compressive strength of metakaolin based geopolymer bricks and
clay bricks were tested in compression testing machine of 400 kN capacity.
Load at failure was taken as the ultimate compressive load. Percentage of water
absorption was calculated after immersing the bricks in water for 24 hours.
Efflorescence was calculated by immersing clay bricks and metakaolin based
geopolymer bricks on their ends in a square tray of 18 cm and depth of 60 cm. It
is ensured that the minimum depth of immersion was 25 cm. The entire setup
was closed with a lid to prevent evaporation of water to the atmosphere. When
water is completely absorbed, a similar quantity of water is placed in the tray
for evaporation. Bricks were examined for efflorescence after second
evaporation.
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Table 5.2 Properties of clay brick and MK-Based GP brick
MK geopolymer
S.No Property Clay brick
brick
1 Size 220×90×70 mm 190×90×90 mm
2 Compressive strength 9.5 N/mm2 5.5 N/mm2
3 Weight 3 kg 2.9 kg
4 Efflorescence Slight nil
5 Initial Rate of Absorption 0.8 Kg/m2/min 0.5 Kg/m2/min
6 Water absorption 10-15% 3-5%
7 Static E of brick 3155 MPa 2340 MPa
8 Dynamic E of brick 3210 MPa 2490 MPa
9 µ of brick 0.21 0.2
Poisson's ratio (µ) is calculated using a quasi-static method of testing of

bricks in compression. Brick specimen in a vertical direction is tested in UTM
of 2000 kN capacity. Dial gauges of Baker make with least count of 0.01mm
and maximum of 25 mm are fixed in three directions and for every increment of
load dial gauge reading is noted. Thin glass pieces are inserted at places of
contact of the dial gauge and brick. As bricks in masonry are subjected to
uniaxial stress or biaxial plane stress, the deformations in lengthwise (220 mm)
and widthwise (70 mm) are considered for calculating Poisson's ratio. Lateral
and longitudinal deformations are noted till 1/3 of the failure load. Three brick
specimens are tested and the average of the values is recorded.
Lateral strain
Poisson's ratio (µ) =
Longitudinal strain
(5.1)
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Dynamic modulus of elasticity of clay brick and metakaolin based

geopolymer brick was calculated by performing Ultrasonic Pulse Velocity test.
Portable Ultrasonic Non- Destructive Digital Indicating Tester (PUNDIT) unit
of model Telsonic ultrasonix UX 4600 pulse velocity was used with a
transducer of 60 kHz of natural frequency. Testing of dynamic modulus of
elasticity using PUNDIT is presented in Figure 5.2. Direct, indirect and surface
transmission methods of testing can be chosen on the basis of the viability in
field conditions. In this study, the direct transmission method was followed to
assess the Dynamic Young's modulus of bricks. The test was conducted in
accordance with IS13311-1(1992) Method of Non-destructive testing of
concrete, Part 1: Ultrasonic pulse velocity.
Figure 5.2 Dynamic Young’s Modulus using PUNDIT
Time taken to travel the path length was digitally displayed. Velocity of
the pulse was calculated using
V = L/T (5.2)
V-Velocity of the pulse in m/s
L-Length of the path travelled in m
T-Time taken in seconds
Taking µ from quasi-static method, dynamic modulus of elasticity is

calculated using
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ρ (1+µ) (1-2µ) V
E=
(1-µ) (5.3)
E = Dynamic Young‟s Modulus of elasticity in MPa
ρ = density in kg/m3 and
V = pulse velocity in m/s.
The properties of clay brick and MK based metakaolin brick is tabulated in

Table 5.2
5.4 Tests on Mortar
Cement mortars of 1:3 ratio by volume were used for the construction of
clay brick masonry and metakaolin based geopolymer bricks. OPC was used for
mortar preparation and sand used was in accordance with IS 2116(1980).
Mortar Cubes of size 150 mm side were cast with water cement ratio of 0.6 in
accordance to IS 2250(1981) Code of practice for preparation and use of
masonry mortars. The compressive strength of mortar cubes was tested after 28
days of water curing in compression testing machine.
Cylinders of 150 mm diameter and 300 mm height were cast with the
mortar used and tested for Young‟s modulus using compressometer. The test
setup used for finding Young's modulus of Elasticity is shown in Figure 5.3.
The compressometer is fitted with a dial gauge of 25mm as largest deformation
and a least count of 0.01mm.
74
Figure 5.3 Test setup for Young’s Modulus of Mortar
Mortar cylinders were loaded up to 1/3 of the ultimate load and

deformations were noted for equal increments of the load. Secant modulus of
elasticity of the mortar was calculated using a slope between 5 to 33 percentage
of ultimate strength in stress-strain graph in accordance with ACI 530-02
Building code requirements for masonry structures.
5.5 Masonry Prisms
Masonry is an assemblage of building units bonded together by mortar. It

is non-homogenous, orthotropic leading to complex mechanical behaviour. In
this study, prisms in axial compression are studied as in most situations brick
masonry experiences axial compression. The performance of metakaolin
modified geopolymer bricks in combination with cement mortar require
investigation as the question about the compatibility of the two is aroused in the
minds. Study of the mechanical behaviour of masonry structures with
metakaolin modified geopolymer bricks gives confidence for the practising
Engineers to use these bricks in construction.
75
Laboratory investigation of masonry prisms was done in accordance with

IS 1905-1987 Indian Standard Brick works-code of practice. Prisms were
constructed with a minimum height of 40cm with a height to thickness ratio of
at least 2 but not more than 5. Correction factors were applied for prisms with
h/t between 2 and 5.
5.5.1 Clay brick masonry prism
Clay bricks were soaked in water for 30 minutes before being placed in
position and used in the construction of prisms in surface dry condition. 10mm
mortar thickness was maintained in joints and beddings. Details of the size, type
of bonding and number of clay prisms used in this study are given in Table 5.3.
As it is customary to test stacked five brick prisms, three prisms of 220 × 390 ×
90 mm in stretcher bond with an aspect ratio of 4.33 were constructed. English
bond is in practice in the construction field and it is relevant to test the prisms in
this bond. Nine prisms in English bond with h/t ratio of 2, 2.77, and 3.8 were
constructed. Photograph of clay brick prisms used in this research is presented
in Figure 5.4. Clay brick masonry was cured for 28 days with water and tested
for compressive strength.
Table 5.3 Dimension of Clay Brick Masonry Prism
S. No Size in mm h/t ratio Bonding No. of prisms

1 220×390×90 4.33 Stretcher 3
2 220×450×220 2.0 English 3
3 690× 610× 220 2.77 English 3
4 690× 810× 220 3.68 English 3
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Figure 5.4 Clay Brick Masonry Prism
Testing of brick masonry prisms was done by Loading frame of 500 kN

capacity and a hydraulic jack of 250 kN. The hydraulic jack was fitted with a
load cell of 250 kN capacity. Deformation in the masonry was measured using
Linearly Varying Displacement Transducer (LVDT) with maximum
deformation that could be measured as 10cm.
LVDT was attached to the prism by means of two L-shaped angles.

Angles were attached to the prisms by steel paste. The surface of the prism was
smoothened by emery sheet to ensure perfect adhesion. Angles were pasted on
to the prisms near the place where maximum deformation was expected. LVDT
and load cell were connected to a data acquisition system which recorded the
data in the computer connected to it.
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Figure 5.5 Test setup for MK Based GP Masonry Prism
5.5.2 Metakaolin Based Geopolymer Brick Prisms
Metakaolin based geopolymer bricks prisms were constructed with 1:3

C.M. with h/t ratio as given in Table 5.4. The experimental setup used testing of
MK based GP masonry prism is presented in Figure 5.5. The thickness of
mortar joints and bedding were maintained at 10 mm. Curing of metakaolin
modified geopolymer brick prisms with water was required for 28 days as
cement mortar in the masonry needs curing. A 10 mm steel sheet was laid on
the top of the prisms before testing for even distribution of load. Masonry was
loaded till it displaces LVDT from its position and then LVDT was removed.
Masonry was continued to load till it fails. Prism types and bonding adopted are
listed in Table 5.4. MK based GP brick prisms used in this study is represented
in Figure 5.6.
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Table 5.4 Dimensions of MK-Based GP Brick Prism
Bonding No. of
S.No Size in mm h/t ratio
type Prisms
1 490×90×190 5.4 Stretcher 3
2 490×190×190 2.57 English 3
3 590×190× 600 3.1 English 3
4 790×190× 600 4.1 English 3
Figure 5.6 MK-based GP Brick Prism

5.1 Metakaolin Based Geopolymer Brick

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68

COMPRESSIVE STRENGTH AND MODULUS OF

5.1 Metakaolin Based Geopolymer Brick

Table 5.1 Mix proportion for Metakaolin Geopolymer brick

1:5 by mass in kg 1:6 by mass in kg

Figure 5.1 Stacking of Trial Bricks

5.2 Clay Bricks

5.3 Tests on Bricks

The properties of bricks were tested in accordance with IS 3495 (1-4)

Table 5.2 Properties of clay brick and MK-Based GP brick

Poisson's ratio (µ) is calculated using a quasi-static method of testing of

Dynamic modulus of elasticity of clay brick and metakaolin based

Figure 5.2 Dynamic Young’s Modulus using PUNDIT

V-Velocity of the pulse in m/s

L-Length of the path travelled in m

T-Time taken in seconds

Taking µ from quasi-static method, dynamic modulus of elasticity is

E = Dynamic Young‟s Modulus of elasticity in MPa

ρ = density in kg/m3 and

V = pulse velocity in m/s.

The properties of clay brick and MK based metakaolin brick is tabulated in

5.4 Tests on Mortar

Figure 5.3 Test setup for Young’s Modulus of Mortar

Mortar cylinders were loaded up to 1/3 of the ultimate load and

5.5 Masonry Prisms

Masonry is an assemblage of building units bonded together by mortar. It

Laboratory investigation of masonry prisms was done in accordance with

5.5.1 Clay brick masonry prism

Table 5.3 Dimension of Clay Brick Masonry Prism

S. No Size in mm h/t ratio Bonding No. of prisms

Figure 5.4 Clay Brick Masonry Prism

Testing of brick masonry prisms was done by Loading frame of 500 kN

LVDT was attached to the prism by means of two L-shaped angles.

Figure 5.5 Test setup for MK Based GP Masonry Prism

5.5.2 Metakaolin Based Geopolymer Brick Prisms

Metakaolin based geopolymer bricks prisms were constructed with 1:3

Table 5.4 Dimensions of MK-Based GP Brick Prism

Figure 5.6 MK-based GP Brick Prism

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