CHAPTER III

METODOLOGY
3.1 Introduction

Interlocking brick structure classifications depend not only on the structure itself but
also properties of interlocking masonry. Thus it is vital to determine characteristics of
materials involved before considering the structural behavior of the structural element.
Masonry physical and mechanical properties depend on various factors such as
physical and mechanical properties of unit and workmanship.
Due to achieve investigation aims as described in objectives, variables such as
workmanship were kept constant. All materials properties were kept in this chapter.
3.2 Properties of interlocking masonry unit
The methodological process which were been carried out in this research meet
objectives and secure proper sequence of study flow. Parameters that have been
looked at in this chapter are testing to find dimension, water absorption, initial rate of
suction, compressive strength, and modulus of rupture. All tests were performed
according to relevant standard which will be discussed below.
3.3 Dimensions
3.3.1 Sampling
24 bricks should be chosen randomly as indicated in Figure 3.3.1.1.
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FIGURE 3.3.1.1 Soil-cement interlocking brick
3.3.2 Equipment
1) Brick, in this project means soil-cement interlocking brick, which should be in the
amount of 24 units.
2) Steel tape, to measure the overall dimension
3.3.3 Measurement of dimensions
Dimensions determination was based on the overall measurement of 24-bricks.
Remove any blisters, small projections, or loose particles of clay adhering to each
brick. Samples should be placed lengthwise in contact with each other in a straight
line upon a flat (level) surface, using the appropriate arrangement for each work size
shown in Figure 3.3.3.1-3.3.3.3.
30


FIGURE 3.3.3.1 Arrangement of bricks for measurement of width

FIGURE 3.3.3.2 Arrangement of bricks for measurement of length
31


FIGURE 3.3.3.3 Arrangement of bricks for measurement of thickness
Overall measurement of 24 brick unites, which will be measured by steel tape,
obey the requirements specified in BS 3921 (British Standards Institute, 1985) as
shown in Table 3.3.3.1. Standard brick unit work size was found to be 215mm
102.5mm 65mm.
TABLE 3.3.3.1 Brick dimension (British Standards Institute, 1985)
Work size
(mm)
Overall measurement of 24 bricks
215.0
102.5
65.0
Limits
Maximum
(mm)
Minimum
(mm)
5235
2505
1605
5085
2415
1515


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3.4 Water absorption
The requirements specified in BS 3921 (British Standards Institute, 1985) for water
absorption. As a consequence of extensive research into the structural performance of
fired-clay masonry, the importance of water absorption as a determinant of its
behaviour in flexure is now recognized.
BS 5628-1 relates three levels of water absorption (less than 7%; between 7%
and 12%; over 12%) to the characteristic flexural strengths to be used in design. A low
water absorption figure is used to classify engineering bricks and bricks for damp-
proof courses but water absorption, like strength, is not a general index of durability.
With many types of clay, the more durable bricks of a given type absorb less water
than those of the same type that are not so durable.
The average value of the water absorptions of ten bricks sampled which was
tested shall meet the stated water absorption and shall in no case be greater than the
water absorption for the appropriate class of brick given in Table 3.4.1.
Table 3.4.1 Classification of bricks by water absorption
Class Water Absorption
% by mass
Engineering A
Engineering B


Damp-proof course 1
Damp-proof course 2


All others No limits
NOTE Damp-proof course 1 bricks are recommended for use in buildings whilst
damp-proof course 2 bricks are recommended for use in external works.
3.4.1 Determination of Water absorption
The method for the determination of water absorption specified in this standard is the
5 hour boiling test. The results obtained from this test are generally lower than, and
are not proportional to, those obtained using the method given in this standard, nor are
they equivalent to each other.

33

3.4.2 Apparatus
1) Ventilated drying oven, complying with the requirements of BS2648.
2) Tank, provided with a grid to ensure free circulation of water between masonry
units and the bottom of the tank.
3) Laboratory balance, capable of weighing to an accuracy of 0.1% of the mass of the
specimen.
3.4.3 Test specimens
Use ten whole bricks as test specimens. Carry out the test using either dry bricks or
bricks that have been subjected to a 24-hour cold immersion test, provided that they
were dried and weighed as described in 3.4.4.
3.4.4 Preparation of specimens
Dry the specimens to constant mass in the oven at a temperature between 110C
and115C as indicated in Figure 3.4.4.1. When cool, weigh each specimen to an
accuracy of 0.1%.

FIGURE 3.4.4.1 10 Bricks in a ventilated oven
34

It can be assumed that heating for at least 48 hour at 110C will assure constant mass,
but it should be noted that several hours may be required before the specimens reach
110C if they are wet when put into the oven. The 48h should be reckoned from the
time the specimens reach 110C. Storage of bricks, unstacked, with spaces between
them, in a ventilated room for a period of 4h, with a current of air from an electric fan
passing over them continuously for at least 2 hour, will cool the specimens to
approximately room temperature.
3.4.5 Test procedure
Place the specimens in a single layer in a tank of water immediately after weighing so
that water can circulate freely on all sides of them. Leave a space of at least 10mm
between adjacent bricks and between bricks and the side of the tank. Heat the water to
boiling point in approximately 1h, boil continuously for 5 hour as shown in Figure
3.4.5.1, and then allow cooling to room temperature by natural loss of heat for not less
than16 hour or more than 19 hour.

FIGURE 3.4.5.1 Water absorption-5 hour boiling test
35

Remove the specimens, wipe off the surface water with a damp cloth, and
weigh. When wiping perforated bricks, they should be shaking to displace water that
might otherwise be left in the perforations. Complete weighing of any one specimen
within 2 minute after its removal from the water is demonstrated in Figure 3.4.5.2.

FIGURE 3.4.5.2 Weighing cooled brick
3.4.6 Calculation of water absorption
Calculate the water absorbed by each specimen, A, expressed as a percentage of the
dry mass, using the following equation:



(3.1)
Calculate the water absorption of the sample, i.e. the average of the water absorptions
for the ten specimens, to the nearest 0.1%.


36

3.5 Initial rate of suction
A suction rate test has been added in BS 3921 (British Standards Institute, 1985),
because in highly stressed masonry structures the initial rate of suction of the bricks
may need to be specified or adjusted by wetting to some predetermined level.
3.5.1 Determination of initial rate of suction
3.5.1.1 Apparatus
1) Large shallow dish, e.g. a photographic dish.
2) Two pieces of metal of equal size, either angle sections or rods.
3.5.1.2 Test procedure
Place the dish on a level table and position the two pieces of metal 75mm to 100mm
apart in the bottom of the dish.
Fill the dish with water until the pieces of metal are covered to a depth of
about 3mm.
Weigh a dry brick to the nearest gram and record the mass m
1
, in grams.
Where double-frogged bricks are being tested, place the brick stretcher face
downwards on the pieces of 1metal. Where other types of brick are being tested, place
the brick bed face downwards on the pieces of metal. Ensure that the depth of
immersion of the face of the brick is maintained at 31 mm. Immersed interlocking
brick immersed in filled-water plate was indicated in Figure 3.5.1.2.1.
37


FIGURE 3.5.1.2.1 An interlocking brick on a plate filled with water
After 60 second, remove the brick, quickly wipe off the surplus water with a
damp cloth, and reweigh the brick to the nearest gram. Record the mass m
2
, in grams.
Measure the length and width of immersed face of the brick in mm and
calculate its gross area A, in mm
2
.Calculate the initial rate of suction, I, in
kg/(m
2
.min), using the following equation

(3.2)
where:
m
1
is the mass of the dry brick (in g);
m
2
is the mass of the wet brick (in g);
A is the area of the immersed face of the brick (in mm
2
).

38

3.6 Compressive strength
According to ASTM: C67 (The American Society for Testing and Material, 1985)
compressive strength can be carried out. Specimen preparation and compressive
strength test, which were explained in part five and seven of ASTM C67 respectively,
stated below:
3.6.1 Specimen Preparation
1) Weight Determination:
2) DryingDry the test specimens in a ventilated oven at 230 to 239F (110 to
115C) for not less than 24 h and until two successive weightings at intervals of 2
hour show an increment of loss not greater than 0.2 % of the last previously
determined weight of the specimen.
3) Coolingafter drying, cool the specimens in a drying room maintained at a
temperature of 75 15F (24 8C), with a relative humidity between 30 and 70 %.
Store the units free from drafts, unstacked, with separate placement, for a period of at
least 4 hour and until the surface temperature is within 5F (2.8C) of the drying room
temperature. Do not use specimens noticeably warm to the touch for any test requiring
dry units. The specimens shall be stored in the drying room with the required
temperature and humidity maintained until tested.
4) An alternative method of cooling the specimens to approximate room temperature
shall be permitted as follows:
Store units, unstacked, with separate placement, in a ventilated room
maintained at a temperature of 75 15F (24 8C), with a relative humidity
between 30 and 70 % for a period of 4 h and until the surface temperature is within
5F (2.8C) of the ventilated room temperature, with a current of air from an electric
fan passing over them for a period of at least 2 hour. The specimens shall be stored in
the ventilated room with the required temperature and humidity maintained until
tested.

39

3.6.2 Test Specimens
3.6.2.1 Brick
The test specimens shall consist of dry half brick (see 3.6.1.2), the full height, and
width of the unit, with a length equal to one half the full length of the unit 1 in.
(25.4mm), except as described below. If the test specimen, described above, exceeds
the testing machine capacity, the test specimens shall consist of dry pieces of brick,
the full height, and width of the unit, with a length not less than one quarter of the full
length of the unit, and with a gross cross-sectional area perpendicular to bearing not
less than 14 in
2
(90.3 cm
2
). Test specimens shall be obtained by any method that will
produce, without shattering or cracking, a specimen with approximately plane and
parallel ends. Five specimens shall be tested.
3.6.2.2 Structural Clay Tile
Test five dry tile specimens in a bearing bed length equal to the width 1 in. (25.4
mm); or test full-size units.
3.6.2.3 Capping Test Specimens
All specimens shall be dry and cool within the meaning of 3.6.1.2 and 3.6.1.3 before
any portion of the capping procedure is carried out.
If the surface which will become bearing surfaces during the compression test
are recessed or panelled, fill the depressions with a mortar composed of 1 part by
weight of quick-hardening cement conforming to the requirements for Type III
cement of Specification C 150, and 2 parts by weight of sand. Age the specimens at
least 48 h before capping them. Where the recess exceeds 1/2 in. (12.7 mm), a brick or
tile slab section or metal plate will be used as a core fill. Cap the test specimens using
one of the two procedures described in 3.6.2.4 and 3.6.2.5.
3.6.2.4 Gypsum Capping
Coat the two opposite bearing surfaces of each specimen with shellac and allow
drying thoroughly. Bed one of the dry shellacked surfaces of the specimen in a thin
coat of neat paste of calcined gypsum (plaster of paris) that has been spread on an
40

oiled non-absorbent plate, such as glass or machined metal. The casting surface plate
shall be plane within 0.003 in. (0.076 mm) in 16 in. (406.4 mm) and sufficiently rigid;
and so supported that it will not be measurably deflected during the capping operation.
Lightly coat it with oil or other suitable material. Repeat this procedure with
the other shellacked surface. Take care that the opposite bearing surfaces so formed
will be approximately parallel and perpendicular to the vertical axis of the specimen
and the thickness of the caps will be approximately the same and not exceeding 1/8 in.
(3.18 mm). Age the caps at least 24 h before testing the specimens.
NOTE 3rapid-setting industrial type gypsum is frequently used for capping.
3.6.2.5 Sulfur-Filler Capping
Use a mixture containing 40 to 60 weight % sulfur, the remainder being ground fire
clay or other suitable inert material passing a No. 100 (150-m) sieve with or without
plasticizer. The casting surface plate requirements shall be as described in 3.6.2.6.
Place four 1-in. (25.4-mm) square steel bars on the surface plate to form a rectangular
mould approximately 1/2 in. (12.7 mm) greater in either inside dimension than the
specimen. Heat the sulfur mixture in a thermostatically controlled heating pot to a
temperature sufficient to maintain fluidity for a reasonable period of time after contact
with the surface being capped. Take care to prevent overheating, and stir the liquid in
the pot just before use. Fill the mould to a depth of 1/4 in. (6.35 mm) with molten
sulphur material. Place the surface of the unit to be capped quickly in the liquid, and
hold the specimen so that its vertical axis is at right angles to the capping surface. The
thickness of the caps shall be approximately the same. Allow the unit to remain
undisturbed until solidification is complete. Allow the caps to cool for a minimum of
2 hour before testing the specimens.
3.6.3 Procedure
1) Test brick specimens flatwise (that is shown in Figure 3.6.3.1; the load shall be
applied in the direction of the depth of the brick). Test structural clay tile specimens in
a position such that the load is applied in the same direction as in service. Centre the
specimens under the spherical upper bearing within 1/6 in. (1.59 mm).
41


FIGURE 3.6.3.1 Flattening surface of interlocking brick
2) The testing machine shall conform to the requirements of Practices 3.4.5.
3) The upper bearing shall be a spherically seated, hardened metal block firmly
attached at the canter of the upper head of the machine. The centre of the sphere shall
lie at the canter of the surface of the block in contact with the specimen.
The block shall be closely held in its spherical seat, but shall be free to turn in
any direction, and its perimeter shall have at least1/4 in. (6.35 mm) clearance from the
head to allow for specimens whose bearing surfaces are not exactly parallel. The
diameter of the bearing surface shall be at least 5 in. (127.00 mm). Use a hardened
metal bearing block beneath the specimen to minimize wear of the lower platen of the
machine. The bearing block surfaces intended for contact with the specimen shall
have hardness not less than HRC60 (HB 620). These surfaces shall not depart from
plane surfaces by more than 0.001 in. (0.03 mm). When the bearing area of the
spherical bearing block is not sufficient to cover the area of the specimen, place a steel
plate with surfaces machined to true planes within 0.001 in. (0.03 mm), and with a
42

thickness equal to at least one third of the distance from the edge of the spherical
bearing to the most distant corner between the spherical bearing block and the capped
specimen.
3) Speed of Testing: Apply the load, up to one half of the expected maximum load, at
any convenient rate, after which, adjust the controls of the machine so that the
remaining load is applied at a uniform rate in not less than 1 nor more than 2 min.
3.6.4 Calculation and Report
1) Calculate and report the compressive strength of each specimen to the nearest 10
psi (0.01 MPa) as follows:
Compressive strength

(3.3)
where:
C = compressive strength of the specimen, lb/in.
2
(Or kg/cm
2
) (Or Pa 10
4
),
W = maximum load, lbf, (or kgf) (or N), indicated by the testing machine, and
A = average of the gross areas of the upper and lower bearing surfaces of the
specimen, in.
2
(or cm
2
).
NOTE 4when compressive strength is to be based on net area (Example: clay floor
tile), substitute for A in the above formula the net area, in in.
2
(or cm
2
), of the fired
clay in the section of minimum area perpendicular to the direction of the load.
2) Calculate and report the average of the compressive strength determinations to the
nearest 10 psi (0.1 MPa).
3) Results must be checked by BS 3921(British Standards Institute, 1974), that brick
can be classified based on compressive strength characteristics as mentioned in Table
3.6.4.1.


43

TABLE 3.6.4.1 Classification on bricks based on strength
Designation Class Average compressive strength not less than
Engineering brick

A
B
N/mm
2
(=MPa)
69.0
48.5
Load bearing brick
15
10
7
5
4
3
2
1
103.5
69.0
48.5
34.5
27.5
20.5
14.0
7.0
Bricks for damp-proof course D.P.C As required
3.7 Modulus of rupture (Flexure Test)
According to ASTM: C67 (The American Society for Testing and Material, 1985)
modulus of rupture, that is shown figure 3.7.1, can be carried out. Specimen
preparation and modulus of rupture (flexure test), which were explained in part five
and six of ASTM C60 respectively, stated below:
44


FIGURE 3.7.1 Modulus of rupture test


45

3.7.1 Specimen Preparation
3.7.1.1 Weight Determination
In order to weighing the samples following steps should be done.
3.7.1.2 Drying
Dry the test specimens in a ventilated oven at 230 to 239F (110 to 115C) for not less
than 24 hour and until two successive weightings at intervals of 2 hour show an
increment of loss not greater than 0.2 % of the last previously determined weight of
the specimen.
3.7.1.3 Cooling
After drying, cool the specimens in a drying room maintained at a temperature of 75
15F (24 8C), with a relative humidity between 30 and 70 %. Store the units free
from drafts, unstacked, with separate placement, for a period of at least 4 hour and
until the surface temperature is within 5F (2.8C) of the drying room temperature. Do
not use specimens noticeably warm to the touch for any test requiring dry units. The
specimens shall be stored in the drying room with the required temperature and
humidity maintained until tested.
3.7.1.4 An alternative method of cooling the specimens to approximate room
temperature which shall be permitted
Store units, unstacked, with separate placement, in a ventilated room maintained at a
temperature of 75 15F (24 8C), with a relative humidity between 30 and 70 %
for a period of 4 h and until the surface temperature is within 5F (2.8C) of the
ventilated room temperature, with a current of air from an electric fan passing over
them for a period of at least 2 hour. The specimens shall be stored in the ventilated
room with the required temperature and humidity maintained until tested.
3.7.2 Test Specimens
The test specimens shall consist of whole dry full-size units (see 3.7.1.2). Five such
specimens shall be tested.
46


3.7.3 Procedure
1) Support the test specimen flatwise unless specified and reported otherwise (that is,
apply the load in the direction of the depth of the unit) on a span approximately 1 in.
(25.4 mm) less than the basic unit length and loaded at midspan. If the specimens have
recesses (panels or depressions) place them so that such recesses are on the
compression side. Apply the load to the upper surface of the specimen through a steel
bearing plate 1/4 in. (6.35 mm) in thickness and 1

in. (38.10 mm) in width and of a

length at least equal to the width of the specimen.
2) Make sure the supports for the test specimen are free to rotate in the longitudinal
and transverse directions of the test specimen and adjust them so that they will exert
no force in these directions.
3) Speed of Testing: The rate of loading shall not exceed 2000 lbf (8896 N)/min. but
this requirement is considered as being met if the speed of the moving head of the
testing machine immediately prior to application of the load is not more than 0.05 in.
(1.27 mm)/min.
3.7.4 Calculation and Report
1) Calculate and report the modulus of rupture of each
2) Specimen to the nearest 1 psi (0.01 MPa) as follows:

(3.4)
where:
S = modulus of rupture of the specimen at the plane of failure, lb
2
/in. (Pa),
W = maximum load indicated by the testing machine, lbf (N),
l = distance between the supports, in. (mm),
47

b = net width, (face to face minus voids), of the specimen at the plane of
failure, in. (mm),
d = depth, (bed surface to bed surface), of the specimen at the plane of failure,
in. (mm), and
x = average distance from the midspan of the specimen to the plane of failure
measured in the direction of the span along the centre line of the bed surface
subjected to tension, in. (mm).
3) Calculate and report the average of the modulus of rupture determinations to the
nearest 1 psi (0.01 MPa).