Upload
enea3000
View
221
Download
0
Embed Size (px)
Citation preview
3.3. Mix design of the repair mortars
Three different compositions were designed for the repair and reintegrations of the 5th
C, the medieval and
the 15th
C mortars. The colours and the textures of the 5th
C and the medieval khorasan mortars were
similar on visual inspections, but however the grading of the coarse brick aggregates and the binder:
aggregate ratios were different. Whereas 15th
C samples were completely different from the standpoint of
their compositions and colours and the textures. The 5th
C and the medieval mortar samples were pinkish-
creamy white with visible coarse brick aggregates whereas the 15thC mortar samples were light grey-
creamy white with only visible medium sized sad. The latter was used with brick pieces inserted in the
mortar in the large joints of the stones in its authentic construction technique.
Fifteen trial mixes for the 5th C samples, 9 trial mixes for the medieval samples and 6 trial mixes for the
15thC samples were designed, produced and casted in 4/4/16 steel moulds. After fixing the binder :
aggregate ratios, the amount of the fine aggregates were adjusted for determining the colour of the lime
paste. The binder was always slaked lime and ground volcanic tuff mixed in 3:1 ratio. The aggregates
were crushed brick and powder and river sand mixed in the ratios of the original sample. The original
ratios of the crushed brick and the river snd were determined by means of evaluation of the data derived
from the acid loss and sieve analysis, and petrographic analysis of the original samples. The amounts
were slightly corrected according to the standard grading (ASTM C 144-99 and TSE 706). Before the
commencement of the preparation of the samples, the aggregates were sieved and grouped according to
mesh sizes and their bulk densities and specific gravities were calculated. In total 72 samples were
prepared for each period making sum of 216 samples which will be conducted to the tests to determine
their physical and mechanical properties after curing periods of one month, three months and six months.
The samples were programmed to be cured in tightly sealed polyethylene bags at 23 2o
C and in 90-100
% RH for 6 months. The only additive which was used was a water reducer (Melment F10, YKS, 0,1 %
in water).
The mortar mixes were mixed by hand untill a homogenous mixture was obtained and vibrated for 15
seconds. The initial setting time was 48 hours for all of the sample groups.
Figure 3.93. The samples of the repair mortars.
80
3.3.1. Properties of the raw materials used in trial mixes
Lime : The water content of the slaked lime was 45 % and this was converted CaO to match the amount.
The lime consisted of 37.90 % Ca(OH)2.
Pozzolana: The pozzolana (ground tuff) which was taken from Konya, was used for the trial mixes. The
ratio of the pozzolana : slaked lime was accepted as 1:3 in regard to the mechanical properties of the
oiginal samples. The chemical composition of the pozzolana was given in the Table 3.14.
Table 3.14. The results of the chemical analysis of the pozzolana (ground volcanic tuff of Konya, Central
Anatolia, Turkey) (*)
(*) N. Koçu, “Konya Çevresindeki Volkanik Tüflerin Yapı Malzemesi Olarak Değerlendirilmesi ve
Özelliklerinin Belirlenmesi Üzerine Bir Araştırma”, Ph.D. Thesis, Institute of Natural Sciences of I.T.U.,
İstanbul, 1997 , page no. 63.
Table 3.15. The results of the XRD Analysis of the volcanic tuff of Konya (I.T.U. Material Science
Laboratory of the Faculty of Chemistry and Metallurgy, Dmax-1000 X-Ray Diffractometer) (*)
Mineral Type Chemical Formula ASTM Card No Jarosite KFe3(SO4)2(OH)6 22-827
Quartz SiO2 33-1161
Silicon Oxide SiO2 29-85
(*) N. Koçu, “Konya Çevresindeki Volkanik Tüflerin Yapı Malzemesi Olarak Değerlendirilmesi ve
Özelliklerinin Belirlenmesi Üzerine Bir Araştırma”, Ph.D. Thesis, Institute of Natural Sciences of I.T.U.,
İstanbul, 1997 , page no. 64.
Name of the
Lab. SiO2 Fe2O3 Al2O3 CaO MgO Na2O TiO2 K2O SO4 AZ SUM L01 HM SM AN
Technical University of İstanbul, Faculty of Mining
65.01 9.41 3.77 0.23 0.08 0.57 - 2.07 5.30 - 86.45 11.92 0.0 4.93 0.40
Seydişehir Aluminium
Factory Chemistry Lab.
68.10 10.86 2.39 0.56 - 0.17 0.80 2.13 8.04 11.28 - - - - -
81
Table 3.16. Evaluation of the results of the XRD Analysis and Minerological Analysis
(I.T.U., Faculty of Mines, Department of Mineralogy) (*)
Mineral Type Chemical Formula Amount of it in the raw
material (%)
Jarosite KFe3(SO4)2(OH)6 60-70
Opal Crystobalite SiO2 15-20
Quartz SiO2 8-10
Amorphous Opal SiO2..nH2O 10-20
Table 3.17. Sieve analysis of the ground volcanic tuff which was used as the pozzolanic additive
Mesh Size (µ) Retained (g) Passed (g)
211 0,0 100
40 38 62
(*) N. Koçu, “Konya Çevresindeki Volkanik Tüflerin Yapı Malzemesi Olarak Değerlendirilmesi ve
Özelliklerinin Belirlenmesi Üzerine Bir Araştırma”, Ph.D. Thesis, Institute of Natural Sciences of I.T.U.,
İstanbul, 1997 , page no. 78.
Table 3.18. Bulk densities and the specific gravities of the aggregates which were used
for the mix designs of the repair mortars
Materials
Bulk Density
(g./cm3)
Specific
Gravity
(g./cm3)
Lime 1.41 2.17
Pozzolana 0.71 2.33
Aggregates Crushed Brick River Sand
B.Density S. Gravity B.Density S. Gravity
8 mm 0.85 1.45
4 mm 0.86 1.43
2 mm 0.87 1.37
1 mm 0.9 2.57 1.53 2.59
0.5 mm 1.05 1.38
0.25 mm 1.04 1.36
<0.25 mm 0.94 1.38
82
3.3.2. Mix designs of the repair mortars
Mix design for the repair mortar to match the 5th
C khorasan mortar :
Sample Code = 5C1-5C2-5C3 (1 month-3 months-6 months old)
Binder : Aggregate = 1:2 as in the original mortar samples
Slaked Lime: Pozzolana = 3:1
Crushed Brick = 40 % of the total aggregates
River Sand = 60 % of the total aggregates
Grading of the aggregates which were used
Mesh size %
16-8 mm 24
8-4 mm 26
4-2 mm 17
2-1 mm 13
1-0,5 mm 9
0.5-0.25 mm 6
<0.25 mm 5
03
7
12
21
36
60
100
0
5
11
20
33
50
76
100
0
8
20
32
42
56
76
100
0
18
34
49
62
74
88
100
0
10
20
30
40
50
60
70
80
90
100
0 0.25 0.5 1 2 4 8 16
mesh size (mm)
Perc
en
tag
e o
f p
assed
(%
)
A
5C
B
C
Figure 3.94. The grading of the aggregates of the 5
th C mortar sample
A,B,C :The ideal amounts of the amount of the passed aggregates were shown in TSE 706- Fuller Parabola,
5C : The passed aggregates of the trial mix for the repair mortar to match the 5th C sample.
83
Mix design for the repair mortar to match the medieval khorasan mortar :
Sample Code = M1-M2-M3 (1 month-3 months-6 months old)
Binder : Aggregate = 1:2 as it was in the original samples.
Slaked Lime: Pozzolana = 3:1
Crushed Brick = 67 % of the total aggregates
River Sand = 33 % of the total aggregates
Grading of the aggregates which were used
Mesh size %
16-8 mm 16
8-4 mm 29
4-2 mm 22
2-1 mm 15
1-0,5 mm 9
0.5-0.25 mm 6
<0.25 mm 3
03
7
12
21
36
60
100
03
9
18
33
55
84
100
0
8
20
32
42
56
76
100
0
18
34
49
62
74
88
100
0
10
20
30
40
50
60
70
80
90
100
0 0.25 0.5 1 2 4 8 16
mesh size (mm)
Perc
en
tag
e o
f p
assed
(%
)
A
M
B
C
Figure 3.95. The grading of the aggregates for the repair mortar to match the medieval samples
A,B,C :The ideal amountss of the passed aggregates were given in TSE 706- Fuller Parabola.
M : Theamount of the passed aggregates of the trial mix for the repair mortar to match the medieval mortar.
84
Mix design for the repair mortar to match the 15th
C khorasan mortar :
Sample Code = 15C1-15C2-15C3 (1 month-3 months-6 months old)
Binder : Aggregate = 1:3 as it was in the original samples.
Slaked Lime: Pozzolana = 3:1
Crushed Brick = 2.35 % of the total aggregates
River Sand = 97.65 % of the total aggregates
Grading of the aggregates which were used
Mesh size %
16-8 mm 0
8-4 mm 0
4-2 mm 26
2-1 mm 21
1-0,5 mm 21
0.5-0.25 mm 25
<0.25 mm 7
0
8
20
34
60
100
0
7
32
53
74
100
0
15
35
57
77
100
0
25
45
67
85
100
0
10
20
30
40
50
60
70
80
90
100
0 0.25 0.5 1 2 4
mesh size (mm)
Perc
en
tag
e o
f p
assed
(%
)
A
15C
B
C
Figure 3.96. The grading of the aggregates for the repair mortar to match the 15
th C mortar
A,B,C :The ideal amountss of the passed aggregates were given in TSE 706- Fuller Parabola.
15C : Theamount of the passed aggregates of the trial mix for the repair mortar to match the 15thC mortar.
85
3.3.3. The physical and mechanical properties of the repair mortars
Table 3.19. Sample code system for the repair mortars prepared in the laboratory of Building Material
Testing of the Faculty of Architecture, I.T.U.
Sample Codes 1 Month Old 3 Months Old 6 Months Old
5th Century 5C1 5C2 5C3
Medieval Age M1 M2 M3
15th Century 15C1 15C2 15C3
The tests for the determination of the physical and mechanical properties will be conducted on the
samples as the ageing tests after 30, 90 and 180 days. Porosimetry (pore size distribution of the repair
mortars will be determined after 180 days). All of the samples were casted in 4/4/16 cm. steel moulds ,
except the samples which were prepared and cured for the compressive which were 7/7/7 cm.
dimensioned cubes. The test conducted in the testing programme for the evaluation of the physical and
mechanical properties and the related samples sizes were given in Table 3.20.
Table 3.20. The tests conducted on the repair mortars for the determination of their physical and
mechanical properties
PHYSICAL PROPERTIES Sample Sizes Standards
Coefficient of Capillarity (g/mm2√s) (4x4x16) x 6
Water Absorption (by weight) (%)
Water Absorption (by volume) (%) TSE 699
Water Absorption in Boil. Water (by weight) (%)
ASTM C20-92
ASTM C97-96
Water Absorption in Boil. Water (by volume) (%) ASTM C 121-90
Density ( g/cm3) ASTM E 12-70
Specific Gravity ( g/cm3)
Porosity (%)
Saturation Degree
Water Vapour Transmission
(Diffusion resistance factor μ ) DIN 52615
MECHANICAL PROPERTIES
Tensile Strength (MPa) (4x4x16) x 6 ASTM C120-90
Compressive Strength (MPa) (7x7x7) x 6 ASTM C170-90
Young’s Modulus (GPa)
AEGING TESTS
Freeze-Thaw cycles (4x4x16) x 6 TSE 699
Crystallisation cycles (4x4x16) x 2
TESTS IN TUBITAK
Porosimetry (mercury intrusion) COULD NOT BE COMMENCED
86
The physical properties tests conducted on the stone, the brick and the mortar samples of the T4 landwalls
of Istanbul. The tests were conducted according to TSE 699 (ASTM C97-96, ASTM C20-92, ASTM C
121-90, ASTM E 12-70).
Figure 3.97. The water absorption capacity Figure 3.98. The water vapour transmission test of
test of the repair mortar samples. the repair mortar samples.
Table 3.21. The results for the physical properties of the 5th
C, medieval and 15th
C repair mortars
μ : Water Vapour Transmission
(Diffusion resistance factor)
Sam.
No
Coef. of
Capill.
(g/mm2s)
Water
Absorp.
(by weight)
(m/m, %)
Water
Absorp.
(by volume)
(v/v, %)
Water
Absorp.
(in boil.wat.)
(m/m, %)
Water
Absorp.
(in boil.wat.)
(v/v, %)
Density
(g/cm3)
Spec.
Gravity
(g/cm3)
Compos
(%)
Poros.
(%)
Sat.
Degree
(%) µ
5C1-1 1.8*10-4 28.97 39.98 32.19 44.32 1.38 59.50 40.5 98.72
5C1-2 1.9*10-4 29.92 41.00 32.19 44.32 1.37 59.00 41.00 100.00
5C1-3 2.3*10-4 29.60 40.55 32.19 44.32 1.37 2.32 59.00 41.00 98.91 21.4521
5C1-4 1.7*10-4 29.59 40.50 33.04 45.22 1.38 59.50 40.50 100.00
5C1-5 3*10-4 29.08 40.13 33.04 45.22 1.38 59.50 40.50 99.09
5C1-6 2.7*10-4 29.67 41.00 33.04 45.22 1.37 59.00 41.00 100.00
M1-1 3*10-4 31.36 42.00 35.07 47.24 1.35 58.00 42.00 100.00
M1-2 4*10-4 30.76 41.40 35.07 47.24 1.36 58.60 41.40 100.00
M1-3 3.5*10-4 31.32 41.40 35.07 47.24 1.36 2.32 58.60 41.40 100.00 18.0497
M1-4 2.3*10-4 31.41 42.00 35.94 47.81 1.35 58.00 42.00 100.00
M1-5 1.9*10-4 32.09 42.30 35.94 47.81 1.34 57.70 42.30 100.00
M1-6 1.8*10-4 31.94 42.30 35.94 47.81 1.34 57.70 42.30 100.00
15C1-1 9.3*10-4 20.42 32.46 23.87 37.64 1.59 64.60 35.40 91.70
15C1-2 9*10-4 21.45 33.67 23.87 37.64 1.57 64.00 36.00 93.53
15C1-3 10*10-4 20.99 32.74 23.87 37.64 1.56 2.46 63.00 37.00 88.49 26.3003
15C1-4 8.8*10-4 20.67 32.86 23.61 37.38 1.59 64.60 35.40 92.83
15C1-5 8.9*10-4 21.44 33.66 23.61 37.38 1.57 64.00 36.00 93.50
15C1-6 9*10-4 21.13 33.17 23.61 37.38 1.57 64.00 36.00 92.14
87
Table 3.22. The average results of the tests conducted for the physical properties of the repair mortars
Sam.
No
Coef. of
Capill.
(g/mm2s)
Water
Absorp.
(by weight)
(m/m, %)
Water
Absorp.
(by volume)
(v/v, %)
Water
Absorp.
(in boil.wat.)
(m/m, %)
Water
Absorp.
(in boil.wat.)
(v/v, %)
Density
(g/cm3)
Spec.
Gravity
(g/cm3)
Compos.
(%)
Poros.
(%)
Sat.
Degree
(%) µ
5C1 2.2*10-4 29.47 40.52 32.61 44.77 1.37 2.32 59.25 40.75 99.44 21.452
M1 2.7*10-4 31.48 41.90 35.50 47.52 1.35 2.32 58.10 41.90 100.00 18.049
15C1 7.7*10-4 21.01 33.09 23.74 37.51 1.56 2.46 64.03 35.97 92.00 26.300
The tests on the mechanical properties of the repair mortars were conducted in the Laboratory of
Building Material Testing, Faculty of Architecture, I.T.U. The mechanical tests were conducted
according to TSE 699 (ASTM C120-90, ASTM C170-90). The determination of compressive
strength tests were conducted by using (Form +Test+Seidner+ Co GMBH, D-7940 Riedlingen
West Germany) universal press with 3000KN capacity (Figure 3.55). And, the determination of
tensile strength tests were conducted by using Mfl Systeme (GMBH, D-6800 Mannheim tester)
with 100KN capacity (Figure 3.100).
The tests were conducted on the samples which were conditioned at the oven at 105oC to constant mass
and on the humid samples, and the moisture contents of the humid samples were given in the Table 3.23;
Fig. 3.99. The universal press for determination of Fig. 3.100. The universal press for
compressive strength of the samples. determination of tensile strength of the samples.
88
Fig. 3.101. “M1”, the result of the Fig. 3.102. “5C1” , the result of the
compressive test. compressive test.
Fig. 3.103. “5C1”, the result of the tensile test. Fig. 3.104. “M1”, the result of the tensile test.
Fig. 3.105. “15C1” , the result of the Fig. 3.106. “15C1” , the result of the
compressive test. compressive test.
89
Table 3.23. The compressive strengths of the repair mortars to match the 5th
C, medieval, and the 15th
C
mortar samples after a month.
Dry
DryDry
9.8 Humid
2.7 % Humid
9.6 % Humid
0
1
2
3
4
5
6
5C1 M1 15C1
Mortar samples
Co
mp
ressiv
e s
tren
gth
(M
Pa)
Figure 3.107. The bar graph of the compressive strengths of the repair mortar samples under humid and
oven dry conditions
Samples Humidity
(%)
Wet Bulk
(g/cm3)
Density
(g/cm3)
Area
(mm2)
Stress (P)
(N)
Compress.
Strength
() (MPa)
Average
(MPa)
5C1-1 0 1.80 1.31 4700.2 7130 1.52 1.53
5C1-2 0 1.80 1.31 4790.02 7330 1.53 (dry)
5C1-3 7.5 % 1.80 1.58 4370.65 3130 0.71
5C1-4 9.5 % 1.80 1.47 4685.35 2250 0.59 0.57
5C1-5 11.50 % 1.80 1.47 4762.31 2800 0.48 (9.6% humid)
5C1-6 10.15 % 1.80 1.50 4622.24 2520 0.50
M1-1 0 1.78 1.34 4828.80 6300 1.30 1.37
M1-2 0 1.78 1.34 4812.19 6980 1.45 (dry)
M1-3 4.5 % 1.78 1.42 4793.96 4680 0.97
M1-4 2 % 1.78 1.38 4751.99 4910 1.03 0.97
M1-5 2.15 % 1.78 1.34 4823.21 4280 0.89 (2.7% humid)
M1-6 2.28 % 1.78 1.36 4872.04 4925 1.01
15C1-1 0 1.90 1.58 4773.93 30,000 6.28 5.82
15C1-2 9.8 % 1.90 1.74 4811.30 17,000 3.53 (dry)
15C1-3 8.8 % 1.90 1.72 4804.35 14,200 2.95
15C1-4 0 1.90 1.58 4851.35 26,000 5.36 3.30
15C1-5 10.5 % 1.90 1.72 4848.96 15,520 3.20 (9.8% humid)
15C1-6 10.2 % 1.90 1.67 4870.46 17,200 3.53
90
Table 3.24. Tensile strengths of the repair mortars to match the 5th
C, medieval, and the 15th
C mortar
samples after a month
Samples Humidity
(%)
Wet Bulk
(g/cm3)
Density
(g/cm3)
Stress (P)
(N)
Tensile
Strength ()
(MPa)
Average
(MPa)
5C1-1 0 1.80 1.37 100 0.23 0.23
5C1-2 8.65 % 1.80 1.46 110 0.27 (dry)
5C1-3 4.15 % 1.80 1.43 110 0.27
5C1-4 0 1.80 1.37 100 0.24 0.27
5C1-5 7.37 % 1.80 1.43 110 0.25 (5.7% humid)
5C1-6 2.91 % 1.80 1.41 130 0.32
M1-1 0 1.78 1.35 145 0.36 0.35
M1-2 2.52 % 1.78 1.38 230 0.56 (dry)
M1-3 3.36 % 1.78 1.40 170 0.41
M1-4 0 1.78 1.35 150 0.35 0.47
M1-5 2.30 % 1.78 1.37 190 0.45 (2.5 % humid)
M1-6 1.78 % 1.78 1.36 200 0.48
15C1-1 0 1.90 1.55 440 1.08 1.16
15C1-2 7.76 % 1.90 1.67 480 1.20 (dry)
15C1-3 7.28 % 1.90 1.67 380 0.93
15C1-4 0 1.90 1.55 520 1.24 0.97
15C1-5 6.05 % 1.90 1.66 370 0.88 (6.57 % humid)
15C1-6 5.20 % 1.90 1.65 370 0.89
Dry Dry
Dry
5.7 % Humid 2.5 % Humid
6,6 Humid
0
1
2
3
4
5
6
5C1 M1 15C1
Mortar samples
Ten
sile s
tren
gth
(M
Pa)
Figure 3.108. The bar graph of the tensile strengths of the repair mortar samples under humid and oven
dry conditions
91
Table 3.25. The results of the ultra sound testing and Young’s modulus’ (static) of the one month old
repair mortar samples to match the 5thC , medieval and 15
thC mortar samples.
Samples Humidity
(%)
Density
(İnitial)(g/cm3)
Density
(g/cm3)
Young’s
Modulus
(GPa)
Average
Young’s Modulus
(GPa)
5C1-1 0 1.80 1.37 17.4*103 17.1*103
5C1-2 1.5 % 1.80 1.42 22.8*103 (dry)
5C1-3 1 % 1.80 1.41 24.1*103
5C1-4 0 1.80 1.37 16.8*103 22.4*103
5C1-5 1.66 % 1.80 1.40 21.8*103 (1.1% humid)
5C1-6 0.5 % 1.80 1.38 20.9*103
M1-1 0 1.78 1.35 19.1*103 19.1*103
M1-2 0.92 % 1.78 1.39 22.9*103 (dry)
M1-3 0.64 % 1.78 1.40 24.1*103
M1-4 0 1.78 1.35 19.1*103 22.6*103
M1-5 2.58 % 1.78 1.45 23.3*103 (1.5% humid)
M1-6 1.86 % 1.78 1.44 20.1*103
15C1-1 0 1.90 1.55 34.80*103 35.33*103
15C1-2 2.7 % 1.90 1.66 39.98*103 (dry)
15C1-3 2.3 % 1.90 1.64 40.14*103 40.06*103
15C1-4 0 1.90 1.55 35.87*103 (2.5 % humid)
D r y
D r y D r y
2 , 5 H u m i d
1 . 5 % H u m i d1 , 1 % H u m i d
0
5 0 0 0
1 0 0 0 0
1 5 0 0 0
2 0 0 0 0
2 5 0 0 0
3 0 0 0 0
3 5 0 0 0
4 0 0 0 0
4 5 0 0 0
5 C 1 M 1 1 5 C 1
M o r t a r s a m p l e s
Yo
un
g's
M
od
ulu
s (M
Pa
)
Figure 3.109. The bar graph of Young’s modulus’ of the repair mortar samples under humid and oven
dry conditions
92
The programme of ageing tests ; The samples were immersed and saturated in water for 24 hours before
the commencement of the freezing and thawing cycles. Consecutively, they were subjected to freezing
cycles of 3 hours at -25oC and thawing in 20
oC water, the samples were kept in water or in the deep-
freeze respectively.
Figure 3.110. The mortar samples after the ageing tests.
Table 3.26. The results of the freeze and thaw cycles of the 5thC, medieval, 15
thC repair mortars
(1 month old).
Number of the freeze and thaw cycles
Samples 1 2 3 4 5 6 7
5C1-1,2,3,4
(5th century)
M1-1,2
(Medieval)
M1-3,4
(Medieval)
15C1-1,2
(15th
century)
15C1-3,4
(15th
century)
Sound
Fissures and micro cracks
Softening at the corners
Flaking, crumbling
Chipping
93
RESULTS AND DISCUSSION
According to the evaluation of the test results of the physical and mechanical properties of the repair
mortars, it was seen that the density, specific gravity, water absorption (by weight), porosity, coefficient
of capillarity and water vapour transmission resistance factor of the samples were compatible with the
original samples. The compressive strength of the 5thC and medieval mortar samples were assumed to be
1-1.5 MPa according to anology established on previous experimental works of the Building Material
Testing Laboratory of the Faculty of Architecture. Standard samples could not be prepared from the
existing joints and exposed parts of the wall core of the T4 (ASTM C270-80a, RILEM 1980), since the
masonry mortars were crumbling and powdering during the sampling procedure. It is programmed to
conduct the point load test (ISRM, 1985, Brook, 1985)
Compressive strengths of the repair mortars are better than the mixes prepared for the 5thC and medieval
samples, although the pozzoulana: slaked lime ratios, the binder: aggregate ratios and the curing
processes were similar. It was seen that the compressive strengths of the repair mortars for the 5th
C and
the medieval fabric were approximately 1.5 MPa where the median for the latter samples was 3.5 MPa.
This deficiency can be related to the existence of the coarse brick aggregates of the repair mortars of the
5thC and medieval parts. It was concluded that the crushed brick pieces had dewatered the medium and
decelarated, even hindered the gel formation it is programmed to follow the gel formation process at the
crushed brick : binder interstices by means of SEM analysis. The repair mortar for the 15thC battlements
included neglectable amount of crushed brick and the gel formation between the sand aggregates were
proceeded in a notable way as compressive strengths of 5.36-6.28 MPa were obtained.
The values obtained for the repair mortars for 5thC and the medieval fabric were satisfactory as they
match the mechanical properties of the original masonry mortars, the initial compressive strength of these
samples should have been gained by the carbonation of the lime on the surfaces of the samples, but since
it was superficial and carbonation of the cores of the samples will be slow and very progressive, the
adhesion of the binder and the aggregates was poor.
The samples will be allowed to the series of silicate forming chemical reactions in the same curing
conditions and will be tested after 90 and 180 days. Provided that the results were satisfactory the mix
designs will be retained otherwise slaked lime : pozzolana ratios will be changed and the amount of the
ground volcanic tuff and the mixing water will be increased, in order to improve the mechanical
properties of the repair mixes for the 5thC and the medieval age.
94
APPENDIX
95
THE TRIAL MIXES FOR KHORASAN MORTARS
96
The 5th
Century Khorasan Mortar Trial Mix 1
Code : 5C1
Date: 1.11.2001
Sample sizes : 3 x (4x4x16)
Binder : Aggregate = 1:2
% 35 Lime
% 70 Aggregates
Amount of the slaked lime = 500 g (Lime has % 45 water in it)
Amount of the aggregates = 1000 g
Amount of the water = 130 ml
The ideal proportions of the aggregates
The % 40 of the total aggregates is crushed brick.
The % 60 of the total aggregates is river sand.
The Sieve Mesh Size Crushed Brick (g)
River Sand (g)
8-16 mm (%24) 320 0
4-8 mm (%26) 88 132
2-4 mm (%17) 60 90
1-2 mm (%13) 36 54
0.5-1 mm (%9) 36 54
0.25-0.5 mm (%6) 32 48
>0.25 mm (%5) 20 30
Total Amount 592 408
The wet bulk = 1.89 g/cm3
Result:
The colour of the samples was too reddish.
97
The Medieval Khorasan Mortar Trial Mix 1
Code : M1
Date: 2.11.2001
Sample sizes : 3 x (4x4x16)
Binder: Aggregate = 1:3
% 25 Lime
% 75 Aggregates
Amount of the slaked lime = 333 g (Lime has % 45 water in it)
Amount of the aggregates = 1000 g
Amount of the water = 170 + 60 =230 ml
The ideal proportions of the aggregates
The % 67 of the total aggregates is crushed brick.
The % 33 of the total aggregates is river sand.
The Sieve Mesh Size Crushed Brick (g)
River Sand (g)
8-16 mm (%16) 320 0
4-8 mm (%29) 147 73
2-4 mm (%22) 100 50
1-2 mm (%15) 60 30
0.5-1 mm (%9) 60 30
0.25-0.5 mm (%6) 53.3 26.7
>0.25 mm (%3) 33.3 16.7
Total Amount 773.6 226.4
The wet bulk = 1.88 g/cm3
Result:
The colour of the samples was too reddish.
98
The 5th
Century Khorasan Trial Mıx 2
Code : 5C2
Date: Mixtures were prepared 5.11.2001and 9.11.2001 casted.
Sample sizes : 3 x (4x4x16)
Binder: Aggregate = 1:2
% 35 Lime
% 70 Aggregates
Amount of the slaked lime = 910 g = 500 g quicklime
Amount of the aggregates = 1000 g
Amount of the water = 110 ml
The ideal proportions of the aggregates
The % 40 of the total aggregates is crushed brick.
The % 60 of the total aggregates is river sand.
The Sieve Mesh Size Crushed Brick (g)
River Sand (g)
8-16 mm 240 0
4-8 mm 104 156
2-4 mm 68 102
1-2 mm 52 78
0.5-1 mm 36 54
0.25-0.5 mm 24 36
>0.25 mm 20 30
Total Amount 544 456
The wet bulk = 1.85 g/cm3
Result:
The colour of the samples was reddish.
99
The Medieval Khorasan Mortar Trial Mix 2
Code : M2
Date: 9.11.2001
Sample sizes : 3 x (4x4x16)
Binder: Aggregate = 1:3
% 25 Lime
% 75 Aggregates
Amount of the slaked lime = 682 g. = 375 g quick lime
Amount of the aggregates = 1125 g
Amount of the water = 200 + 25 =230 ml
The ideal proportions of the aggregates
The % 67 of the total aggregates is crushed brick.
The % 33 of the total aggregates is river sand.
The Sieve Mesh Size Crushed Brick (g)
River Sand (g)
8-16 mm 180 0
4-8 mm 218.58 107.67
2-4 mm 165.82 81.68
1-2 mm 11306 55.69
0.5-1 mm 67.84 33.41
0.25-0.5 mm 45.22 22.28
>0.25 mm 2261 11.14
Total Amount 813.13 311.87
The wet bulk = 1.98 g/cm3
Result:
The colour of the samples was reddish.
100
The 5th
Century Khorasan Mortar Trial Mix 3
Code : 5C3
Date: Mixtures were prepared 16.11.2001and 18.11.2001 casted.
Sample sizes : 3 x (4x4x16)
Binder: Aggregate = 1:2
% 35 Lime
% 70 Aggregates
Puzzolana: Binder = 1:2
Amount of the slaked lime = 607 g = 334 g quick lime
Amount of the pozzolana = 167 g
Amount of the aggregates = 1000 g
Amount of the water = 164 ml
The ideal proportions of the aggregates
The % 40 of the total aggregates is crushed brick.
The % 60 of the total aggregates is river sand.
The Sieve Mesh Size Crushed Brick (g)
River Sand (g)
8-16 mm 240 0
4-8 mm 104 156
2-4 mm 68 102
1-2 mm 52 78
0.5-1 mm 44 66
0.25-0.5 mm 36 54
>0.25 mm 0 0
Total Amount 544 456
Result:
The colour of the samples was too yellow. The brick powder (>0.25 mm) must have been added. The
amount of lime was not enough. The result was unsuccessful.
101
The 5th
Century Khorasan Mortar Trial Mix 4
Code : 5C4
Date: Mixtures were prepared 22.11.2001and 23.11.2001 casted.
Sample sizes : 3 x (4x4x16)
Binder: Aggregate = 2:3
% 35 Lime
% 70 Aggregates
Amount of the slaked lime = 910 g. = 500 g quick lime
Amount of the pozzolana = 120+30 =150 g
Amount of the aggregates = 1000 g
Amount of the water = 170+30 =200 ml
The ideal proportions of the aggregates
The % 40 of the total aggregates is crushed brick.
The % 60 of the total aggregates is river sand.
The Sieve Mesh Size Crushed Brick (g)
River Sand (g)
8-16 mm 240 0
4-8 mm 104 156
2-4 mm 68 102
1-2 mm 52 78
05-1 mm 36 54
0.25-0.5 mm 24 36
>0.25 mm 20 30 (puzzolana)
Total Amount 544 456
The wet bulk = 1.87 g/cm3
Result:
The colour of the samples was yellow.
102
The 5th
Century Khorasan Mortar Trial Mix 5
Code : 5C5
Date: 22-23.11.2001
Sample sizes : 3 x (4x4x16)
Binder: Aggregate = 1:2
% 35 Lime
% 70 Aggregates
Amount of the slaked lime = 910 g. = 500 g quick lime
Amount of the pozzolana = 160 g
Amount of the aggregates = 1000 – 160 = 840 g
Amount of the water = 136 ml
Amount of the water reducing additive = 1/1000 of amount of water (Melment F10)
The ideal proportions of the aggregates
The % 40 of the total aggregates is crushed brick.
The % 60 of the total aggregates is river sand.
The Sieve Mesh Size Crushed Brick (g)
River Sand (g)
8-16 mm 201.6 0
4-8 mm 87.4 131
2-4 mm 57.1 85.7
1-2 mm 43.7 65.5
0.5-1 mm 30.2 45.4
0.25-0.5 mm 20.2 30.3
>0.25 mm 16.8 25.2
Total Amount 457 383
The wet bulk = 1.80 g/cm3
Result: (Satisfactory)
The colour of the samples was red enough.
The result was successful.
103
The Medieval Age Khorasan Mortar Trial Mix 3
Code : M3
Date: 27.11.2001
Sample sizes : 3 x (4x4x16)
Binder: Aggregate = 1:2 (Decided)
% 25 Lime
% 75 Aggregates
Amount of the slaked lime = 909 g. = 500 g quick lime
Amount of the pozzolana= 160 g
Amount of the aggregates = 840 g
Amount of the water reducing additive = 1/1000 of amount of water (Melment F10)
Amount of the water = 150 ml
The ideal proportions of the aggregates
The % 67 of the total aggregates is crushed brick.
The % 33 of the total aggregates is river sand.
The Sieve Mesh Size Crushed Brick (g)
River Sand (g)
8-16 mm 134.4 0
4-8 mm 163.20 80.39
2-4 mm 123.82 60.98
1-2 mm 84.43 41.58
0.5-1 mm 50.65 24.94
0.25-0.5 mm 33.76 16.63
>0.25 mm 16.90 8.32
Total Amount 607.16 232.84
The wet bulk = 1.77 g/cm3
Result: (Satisfactory)
The colour of the samples was red enough.
The result was successful.
104
The 15th
Century Khorasan Mortar Trial Mix 1
Code : 15C1
Date: 03.12.2001
Sample sizes : 3 x (4x4x16)
Binder: Aggregate = 1:3 (Decided)
% 25 Lime
% 75 Aggregates
Amount of the slaked lime = 605.45 g = 333 g quick lime
Amount of the pozzolana= 110 g
Amount of the aggregates = 890 g
Amount of the water reducing additive = 1/1000 of amount of water (Melment F10)
Amount of the water = 150 ml
The ideal proportions of the aggregates
The Sieve Mesh Size
River Sand (g)
8-16 mm 0
4-8 mm 0
2-4 mm 0
1-2 mm 156.6
0.5-1 mm 156.6
0.25-0.5 mm 420
>0.25 mm 156.6
Total Amount 890
The wet bulk = 1.85 g/cm3
Result: (Unsatisfactory)
The colour of the samples was too yellow .
105
The 15th
Century Khorasan Mortar Trial Mix 2
Code : 15C2
Date: prepared in 28.12.2001, casted in 30.12.2001.
Sample sizes : 2 x (4x4x16)
Binder: Aggregate = 1:3 (Decided)
% 25 Lime
% 75 Aggregates
Amount of the slaked lime = 454.54 g. = 250 g quick lime
Amount of the pozzolana= 80 g
Amount of the aggregates = 670 g
Amount of the water reducing additive = 1/1000 of amount of water (Melment F10)
Amount of the water = 80 ml
The ideal proportions of aggregates
The Sieve Mesh Size
Crushed Brick (g)
River Sand (g)
8-16 mm 0 0
4-8 mm 0 0
2-4 mm (%20) 67 67
1-2 mm (%22) 74 74
0.5-1 mm (%23) 0 154
0.25-0.5 mm (%32) 0 214.5
>0.25 mm (%3) 0 20.1
Total Amount 141 529
The wet bulk = 1.97 g/cm3
Result: (Unsatisfactory)
The colour of the samples was yellow .
106
The 5th
Century Khorasan Mortar (Decided Mix)
Code : 5C5
Date: prepared in 26.12.2001, casted in 27.12.2001
Sample sizes : 18 x (4x4x16) + 6x (7x7x7)
Binder: Aggregate = 1:2
% 35 Lime
% 70 Aggregates
Amount of the slaked lime = 5559.32 g
Amount of the pozzolana = 977.55 g
Amount of the aggregates = 5132.14 g
Amount of the water = 831 ml
Amount of the water reducing additive = 1/1000 of amount of water (Melment F10)
The ideal proportions of the aggregates
The % 40 of the total aggregates is crushed brick.
The % 60 of the total aggregates is river sand.
The Sieve Mesh Size Crushed Brick (g)
River Sand (g)
8-16 mm (%24) 1231.71 0
4-8 mm (%26) 533.74 800.61
2-4 mm (%17) 348.98 523.48
1-2 mm (%13) 266.90 400.31
0.5-1 mm (%9) 184.76 277.14
0.25-0.5 mm (%6) 123.17 184.76
>0.25 mm (%5) 102.64 153.97
Total Amount 2792 2340
The wet bulk = 1.78 gr/cm3
107
The Medieval Age Khorasan Mortar (Decided Mix)
Code : M3
Date: prepared in 27.12.2001, casted in 30.12.2001.
Sample sizes : 18 x (4x4x16) + 6x (7x7x7)
Binder: Aggregate = 1:2 (Decided)
% 25 Lime
% 75 Aggregates
Amount of the slaked lime = 5516.7 g
Amount of the pozzolana= 971.25 g
Amount of the aggregates = 5099.06 g
Amount of the water reducing additive = 1/1000 of amount of water (Melment F10)
Amount of the water = 913 ml
The ideal proportions of the aggregates
The % 67 of the total aggregates is crushed brick.
The % 33 of the total aggregates is river sand.
The Sieve Mesh Size Crushed Brick (g)
River Sand (g)
8-16 mm (%16) 815.86 0
4-8 mm (%29) 990.70 488.0
2-4 mm (%22) 751.60 370.20
1-2 mm (%15) 512.40 252.40
0.5-1 mm (%9) 307.50 151.40
0.25-0.5 mm (%6) 205.00 101.00
>0.25 mm (%3) 102.50 50.50
Total Amount 3685.55 1413.50
The wet bulk = 1.78 g/cm3
108
The 15th
Century Khorasan Mortar (Decided Mix)
Code : 15C3
Date: prepared in 04.01.2002, casted in
Sample sizes : 18 x (4x4x16) + 6x (7x7x7)
Binder: Aggregate = 1:3 (Decided)
% 25 Lime
% 75 Aggregates
Amount of the slaked lime = 4778 g
Amount of the pozzolana= 841 g
Amount of the aggregates = 7040 g
Amount of the water reducing additive = 1/1000 of amount of water (Melment F10)
Amount of the water = 80 ml
The ideal proportions of the aggregates
The % 2.35 of the total aggregates is crushed brick.
The % 97.65 of the total aggregates is river sand.
The Sieve Mesh Size
Crushed Brick (g)
River Sand (g)
8-16 mm 0 0
4-8 mm 0 0
2-4 mm (%26) 91.52 (%5) 1738.7
1-2 mm (%21) 74 (%5) 1404.4
0.5-1 mm (%21) 0 1478.4
0.25-0.5 mm (%25) 0 1760
>0.25 mm (%7) 0 493
Total Amount 165.52 6874.5
The wet bulk =1.90 g/cm3