Mix Design of the Repair Mortars

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




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




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.


Crushed Brick = 67 % of the total aggregates

River Sand = 33 % of the total aggregates


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.


Crushed Brick = 2.35 % of the total aggregates

River Sand = 97.65 % of the total aggregates


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


Binder: Aggregate = 1:3

% 25 Lime

% 75 Aggregates

Amount of the slaked lime = 333 g (Lime has % 45 water in it)


Amount of the water = 170 + 60 =230 ml





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


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.



% 35 Lime

% 70 Aggregates

Amount of the slaked lime = 910 g = 500 g quicklime







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



Result:

The colour of the samples was reddish.

99

The Medieval Khorasan Mortar Trial Mix 2

Code : M2

Date: 9.11.2001



% 25 Lime

% 75 Aggregates

Amount of the slaked lime = 682 g. = 375 g quick lime


Amount of the water = 200 + 25 =230 ml





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



Result:

The colour of the samples was reddish.

100

The 5th


Code : 5C3




% 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







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


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


Code : 5C4




% 35 Lime

% 70 Aggregates


Amount of the pozzolana = 120+30 =150 g


Amount of the water = 170+30 =200 ml





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)



Result:

The colour of the samples was yellow.

102

The 5th


Code : 5C5

Date: 22-23.11.2001



% 35 Lime

% 70 Aggregates


Amount of the pozzolana = 160 g

Amount of the aggregates = 1000 – 160 = 840 g


Amount of the water reducing additive = 1/1000 of amount of water (Melment F10)





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



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


Binder: Aggregate = 1:2 (Decided)

% 25 Lime

% 75 Aggregates


Amount of the pozzolana= 160 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



Result: (Satisfactory)

The colour of the samples was red enough.

The result was successful.

104

The 15th


Code : 15C1

Date: 03.12.2001



% 25 Lime

% 75 Aggregates

Amount of the slaked lime = 605.45 g = 333 g quick lime






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


Result: (Unsatisfactory)

The colour of the samples was too yellow .

105

The 15th


Code : 15C2

Date: prepared in 28.12.2001, casted in 30.12.2001.



% 25 Lime

% 75 Aggregates

Amount of the slaked lime = 454.54 g. = 250 g quick lime





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



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)


% 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







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


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.



% 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







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


108

The 15th

Century Khorasan Mortar (Decided Mix)

Code : 15C3

Date: prepared in 04.01.2002, casted in



% 25 Lime

% 75 Aggregates

Amount of the slaked lime = 4778 g






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


The wet bulk =1.90 g/cm3

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