3.3. Designing and Production of the Repair Mortars Three different - PowerPoint PPT Presentation

3.3. Designing and Production of the Repair Mortars Three different compositions were designed for the repair and reintegrations of the 5 th C, the medieval and the 15 th C mortars. The colours and the textures of the 5 th 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 15 th C samples were completely different from the standpoint of their compositions and colours and the textures. The 5 th C and the medieval mortar samples were pinkish-creamy white with visible coarse brick aggregates whereas the 15 th C 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 5 th C samples, 9 trial mixes for the medieval samples and 6 trial mixes for the 15 th C 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 A 2 o 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.

3.3.1. Properties of the Raw Materials Used in the Trial Mixes Lime : The water content of the slaked lime was 45 % and this was converted CaO to match the original binder 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 3.5. Table 3.5. The results of the chemical analysis of the pozzolana (ground volcanic tuff of Konya, Central Anatolia, Turkey) (*) Name of the SiO 2 Fe 2 O 3 Al 2 O 3 CaO MgO Na 2 O TiO 2 K 2 O SO 4 AZ SUM L01 HM SM AN Lab. Technical University of Ýstanbul, 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 Faculty of Mining Seydiþehir Aluminium Factory 68.10 10.86 2.39 0.56 - 0.17 0.80 2.13 8.04 11.28 - - - - - Chemistry Lab.

Table 3.6. 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 KFe 3 (SO 4 ) 2 (OH) 6 22-827 Quartz SiO 2 33-1161 Silicon Oxide SiO 2 29-85 Table 3.7. Evaluation of the results of the XRD Analysis and Minerological Analysis (I.T.U., Faculty of Mines, Department of Mineralogy) (*) Mesh Size (µ) Retained (g) Passed (g) 211 0,0 100 40 38 62 Figure 3.56. SEM micrograph of the Konya volcanic tuff Figure 3.57. EDX diagram of the Konya Volcanic tuff dust, quartz crystal on the right. (Tuff dust is composed of fines around 3-5 microns size)

Pozzolanic Activity Test : Table 3.8. Compressive strengths of the samples after 1, 2 weeks and a month Compressive Curing Dimensions Compression Strength The Samples Time (cm) Stress (N) (MPa) Sample 1 1 week 7/7/7 97.400 19.63 Sample 2 2 weeks 7/7/7 104.000 20.96 Sample 3 1 month 7/7/7 99.000 20.06 Table 3.9. Tensile strengths of the samples after 1, 2 weeks and a month Curing Dimensions Tensile Tensile The Samples Time (cm) Stress (N) Strength (MPa) Sample 1 1 week 4/4/16 1380 4.85 Sample 2 2 weeks 4/4/16 1650 5.86 Sample 3 1 month 4/4/16 1730 6.05

Mix design for the repair mortar Mix design for the repair mortar Mix design for the repair mortar to match the 5 th century khorasan to match the 15 th century khorasan to match the medieval khorasan mortar ; mortar ; mortar ; Sample Code = M1-M2-M3 Sample Code = 5C1-5C2-5C3 Sample Code = 15C1-15C2-15C3 (1 month-3 months-6 months old) (1 month-3 months-6 months old) (1 month-3 months-6 months old) Binder : Aggregate = 1:2 Binder : Aggregate = 1:2 Binder : Aggregate = 1:3 Slaked Lime: Puzzolana = 3:1 Slaked Lime: Puzzolana = 3:1 Slaked Lime: Puzzolana = 3:1 Crushed Brick = 67 % of the total agg. Crushed Brick = 40 % of the total agg. Crushed Brick = 2.35 % of the total agg. River Sand = 33 % of the total agg. River Sand = 60 % of the total agg. River Sand = 97.65 % of the total agg. 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 90 88 90 90 88 84 85 80 80 80 76 74 Percentage of passed (%) 77 Percentage of passed (%) 76 76 Percentage of passed (%) 74 74 70 70 70 67 62 A 60 60 A 62 A 60 60 60 60 56 M 55 57 56 15C 5C 53 50 49 B 50 50 50 B B 49 C 45 42 C 40 C 42 40 40 36 34 36 33 35 32 34 34 33 30 32 32 30 30 25 21 20 20 18 18 20 20 21 20 20 20 18 15 12 10 12 9 11 8 10 10 7 8 8 7 7 3 3 5 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.25 0.5 1 2 4 8 16 0 0.25 0.5 1 2 4 0 0.25 0.5 1 2 4 8 16 mesh size (mm) mesh size (mm) mesh size (mm) The grading of the aggregates of the The grading of the aggregates The grading of the aggregates for the 5 th century mortar sample repair mortar to match the 15 th for the repair mortar to match the medieval samples century mortar

Table 3.10. Sample code system for the repair mortars prepared in the laboratory of Material Testing of the Faculty of Architecture, I.T.U. Sample Codes 1 Month Old 3 Months Old 6 Months Old 5 th Century 5C1 5C2 5C3 Medieval Age M1 M2 M3 15 th 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.

3.3.3. Experimental Works for the Repair Mortars The tests conducted on the repair mortars for the determination of their physical and mechanical properties : The tests conducted on the repair mortars : I. Physical Properties : II. Mechanical Properties: III. Aeging Tests : Coefficient of Capillarity Compressive Strength Freeze-Thaw Cycles Water Absorption (by weight) Tensile Strength Crystallisation Cycles Young’s Modulus Water Absorption (by volume) Water Absorption in Boiled Water (by weight) Shrinkage Water Absorption in Boiled Water (by volume) Density Specific Gravity Adherence Strength Water Absorption (by weight) Water Absorption (by volume) . Composity Porosity Saturation Degree Water Vapour Transmission . Porosimetry

3.3.3.1.Qualitative and Semi- Quantitative Analysis of the Water-Soluble Salts of the Repair Mixes Table 3.11. The results of the quantitative analysis of the water soluble salts and the conductivity tests of the repair mortars Conductance ( m s) Cl - -2 -2 Sample SO 4 CO 3 NO 3 5C1 ++ - - - 348 5C2 ++ - - - 1097 5C3 ++ - - - 1481 M1 ++ - - - 123 M2 ++ - - - 1556 M3 ++ - - - 1786 15C1 + - - - 72 15C2 + - - - 1497 15C3 + - - - 974 3.3.3.2. The Micro and Macro Analysis of the Repair Mortars • Petrology of the repair mortars of 5 th Century after 3 and 6 months of curing time : Fig. 3.58. General structure of phase between Fig. 3.59. The binding phase between two aggregates aggregate and binder of the repair mortar of the repair mortar of 5 th C. after 6 months of curing for 5 th C. after 6 months of curing time time

Fig. 3.60. The adhesion between the crushed Fig. 3.61. Binder , coarse aggregates (quartz brick and the binder of the repair mortar of and brick pieces) fine aggregates (tuff dust) 5thC. after 6 months of curing time Fig. 3.63. A piece of tuff in the dusty form of Fig. 3.62. General structure of the repair repair mortar of 5 th C. after 3 months of of 5 th C. after 3 months of curing mortar curing time time