DEVELOPMENTOF CEMENT STABILIZED MASONRY
INTERLOCKING BLOCKS USING ALUMINIUM
HYDROXIDE AND GRANITE POWDER AS ADDITIVES
PROJECT REFERENCE NO.: 40S_BE_0954
COLLEGE : THE NATIONAL INSTITUTE OF ENGINEERING, MYSORE
BRANCH : DEPARTMENT OF CIVIL ENGINEERING
GUIDE
: PROF.T. H. SADASHIVA MURTHY
STUDENTS : MS. NAVYASHREE K.C.
MR. ABHISHEK M.V.
MR. PAVAN P.
MR. SURYA H.R.
Introduction:
Huge quantities of construction materials are required in developing countries due to
continued
infrastructural growth and inturn large quantities of construction wastes are
generated every year. Wastes are also generated from various industries such as iron slag
from steel industries, aluminium hydroxide from aluminium industries etc. The disposal of
these wastes is a very serious problem because these wastes requires huge space for its
disposal and pollutes the environment.Hence lot of research works need to be carried out to
investigate to use these wastes as construction materials. Aluminium hydroxide and granite
powder are two such industrial wastes generated in large quantities.
Aluminium hydroxide is the waste generated during aluminium production. From the
literature it is observed that aluminium hydroxide is added to cement as stabilizer and to soil
as flocculating agent. Aluminium hydroxide is not extremely sensitive to moisture content
variations and is also used as fire retardant filler. These are the desirable properties for
additives used in soil stabilization.
Granite powder is obtained from the granite slurry generated in granite processing
industry.Granite powder has SiO2as the major component and small amount of calcium oxide
which helps in the stabilization and hydration with cement. The grain size and specific
gravity of granite powder is also suitable as an additive to cement.Since granite powder
possess cementitious properties, it can be used as an additive with cement to develop soil
cement stabilized masonry interlocking blocks.
From the literature it was observed that Granite powder can be added in the range of
25-30% as an additive to soil and cement to get the optimum strength of soil stabilized block.
Aluminium hydroxide can be added in the range of 4 - 10% as an additive to soil and
cement to get the optimum strength of soil stabilized block.
Hence this project intends to study the possibility of using aluminium hydroxide and
granite powder as additives in the development of interlocking blocks.
Objectives:
The main objectives of project are:
 To arrive at optimum mix proportion of soil, cement, aluminum hydroxide and granite
powder as additives in various proportions to get better strength.
 To design the size and shape of the mould to obtain the interlocking blocks with
suitable keys for better interlocking system.
 To develop interlocking blocks using the pre-obtained optimum proportion.
 To study the behaviour of interlocking blocks for compression, impact resistance,
water absorption and sorptivity.
 To study the compressive strength of masonry prism.
Methodology:
1. Preliminary studies.
a. Material characterization:
Suitable tests have beenconducted on cement, soil, aluminium hydroxide and granite
powder to characterize their properties.
b. Mix design:
The optimum proportion of the above materials are obtained for required compressive
strengthof block based on different levels of combinations of additives. The required
amount of water based on optimum moisture content (OMC) is added and thoroughly
mixed to obtain a uniform consistent mixture. This mixture is used to produce the
interlocking blocks using “Mardini press”- block making machine. From this the
optimum mix proportion which gave better strength was considered for detailed
studies of interlocking block.
2. Detailed studies.
The optimum mix proportion obtained by preliminary studies was used for the
development of interlocking blocks.
Interlocking block of specific size and shape with suitable interlocking keys is as
shown in the figure.1 was cast and cured for 28 days.
The masonry blocks have been studied for various properties such as
 Compressive strength
 Impact resistance
 Water absorption
 Sorptivity
The compressive strength of the masonry prisms made by these interlocking blocks is also to
be studied.
Suitable test to study the water ingress were conducted.
All dimensions are in inches
Results and conclusion:
Table 1Compressive test results of preliminary studies.
Block Designation M
a
t
e
r
i
a
l
C e m e n t Granite Powder Aluminium Hydroxide S o i
(%)
(%)
(%)
(%)
C
1 1
0 3
0 1
0 5
C
2 1
0 3
0
8
5
s 7 day average compressive strength
(MPa)
l
28 day average compressive strength
(MPa)
0 1 . 9 3 1 . 8 5
2 2 . 1 0 1 . 9 6
C
C
C
C
C
C
C
C
C
C
1
1
1
3
4
5
6
7
8
9
0
1
2
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
3
3
2
2
2
2
2
2
2
2
0
0
5
5
5
5 1
0
0
0
0 1
6
4
4
6
8
5
5
6
5
5
0 5
6
6
6
0 6
4
6
8
4
6
1
9
7
5
6
4
2
0
2
3
3
2
1
2
2
2
2
1
.
.
.
.
.
.
.
.
.
.
9
7
1
8
7
0
6
6
1
7
4
0
6
3
0
7
9
1
8
4
4
4
4
4
2
2
4
4
3
2
.
.
.
.
.
.
.
.
.
.
1
5
4
3
7
8
2
3
2
8
4
8
5
6
2
3
5
6
7
3
The blocks with 25-30% granite powder,3- 4% aluminium hydroxide and 10%
cement showed higher strength.. It is found that with the increase in quantity of aluminium
hydroxide the strength of blocks decreased. This decrease is possibly due to the increase in
fineness of the mix. Hence M-sand was added to make it coarse.
Compressive test results of interlocking blocks.
Table 2. Compressive strength of blocks of detailed study
Block designation
C e m e n t
(%)
Granite Powder
(%)
Al2(OH)3
(%)
S o i l
(%)
M-sand
(%)
SM (CB)
10
-
-
45
45
GSM
10
30
-
24
36
GASM 1
10
25
3
50
12
GASM 2
10
25
3
44
18
GASM 3
10
30
4
28
28
GASM 4
10
30
4
22
34






2
8
Weight
(kg)
11.32
11.56
11.38
11.65
11.16
11.64
11.42
11.32
11.29
11.220
11.22
11.23
11.53
11.18
11.44
11.22
11.77
11.36
d
a
Strengt h
(Mpa)
6 . 0 2
6 . 7 0
6 . 1 6
5 . 7 2
5 . 6 5
5 . 8 0
5 . 1 4
5 . 2 4
5 . 2 1
5 . 2 0
5 . 2 5
5 . 0 9
4 . 9 5
4 . 2 3
4 . 8 3
3 . 8 9
4 . 8 7
4 . 7 6
y
s
Average
Strength(Mpa)
The compressive strength of control block was found to be 6.3 MPa.
The block GSM with 30% granite powder shows a compressive strength of 5.72 MPa.
It can be noted that with the addition of 30% of granite powder to Control Block (CB)
a decrease in strength by 9.21 % can be seen. So the addition of granite powder to the
soil stabilized block decreases its compressive strength.
The blocks GASM1 , GASM2 with 3% aluminium hydroxide and 25% granite powder
shows a compressive strength of 5.2 MPa.
By the addition of 3% of aluminium hydroxide to the control Block and GSM the
compressive strength decreases by 9.25%.
And by the addition of 4% of aluminium hydroxide to the Control Block and GSM the
compressive strength decreases by 19.3%.
6.3
5.72
5.2
5.18
4.7
4.5




Hence block with only granite powder shows a decrease in compressive strength of
9.21%.
Hence block with both 25-30% granite powder and 3-4% aluminium hydroxide shows a
decrease in compressive strength when compared to the control block
Hence by the addition of aluminium hydroxide and granite powder decreases the
compressive strength of soil stabilized block.
According to IS 1077:1992,section 4.1 the blocks GASM1,GASM2,GSM and SM can
be categorized as Class 5 and can be used for suitable construction purposes.
Water Absorption test
Table 3 Water absorption test results
Block designation
GASM 1
GASM 2
GASM 3
GASM 4
GSM
SM




Sl.no.
Initial Weight
(kg)
Final Wieght (w2) kg
Water absorption (%) Average (%)
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
8.285
8.298
8.306
8.565
8.396
8.425
8.285
8.288
8.312
8.402
8.356
8.348
8.110
7.960
8.040
8.050
8.185
8.005
8.890
8.903
9.005
9.124
8.960
8.966
8.962
8.920
8.980
9.125
9.028
8.930
9.260
9.165
9.265
9.105
9.215
9.095
7.302
7.290
8.415
6.526
6.710
6.420
8.171
7.625
8.036
8.605
8.042
6.971
14.180
15.138
15.236
13.105
12.583
13.616
7.669
6.532
7.944
7.872
14.851
13.101
The blocks GASM 1 to GASM 4 in which aluminium hydroxide is added have water
absorption value of 6-8%.
The blocks GSM and SM where alluminium hydroxide is not added have water
absorption value of 13-14%.
Hence the addition of aluminium hydroxide decreases the water absorption capacity of
the blocks.
As per IS 1077:1992,section 7.2,the bricks, when tested in accordance with the procedure
laid down in IS 3495 (part 2):1992 after immersion in cold water for 24 hours,water
absorption shall not be more than 20% by weight upto Class 12.5 and 15% by weight for
higher classes.All blocks tested fall under Class 5 and have water absorption capacity
within 15% satisfying the provision of the code IS 1077:1992,section 7.2. Hence these
blocks can be used for construction purpose.
Prism test
Table 4:Prism test results
Block
Load at first crack
designation
(kN)
GASM 1 5 4 . 2 5
GASM 2 4 9 . 0 0
GASM 3 2 7 . 8 0
Impact test
Table 5:Impact test results
S l n o . Block designation



1
GASM 1
2
GASM 2
3
GASM 3
4
GASM 4
5
GSM
6
SM
Impact face
Side face
Key face
Width face
Side face
Key face
Width face
Side face
Key face
Width face
Side face
Key face
Width face
Side face
Key face
Width face
Side face
Key face
Width face
Ultimate load Compressive strength
(kN)
of prism(MPa)
8 4 . 0 0 1
.
9
2
2
9 3 . 0 0 2
.
1
2
8
7 4 . 3 0 1
.
7
0
0
Number
First crack
1
1
5
0
5
1
2
4
6
6
1
5
2
5
1
2
1
2
1
4
4
1
1
5
0
6
1
5
3
8
8
of blow s
At failure
8
0
5
0
1
4
8
0
4
6
1
9
2
1
2
5
2
4
2
3
1
4
9
8
0
5
0
2
1
5
0
4
0
2
4
Impact energy at first crack
(N-m)
113.925
588.323
48.265
124.282
541.117
57.918
155.352
294.116
115.836
124.282
164.704
38.612
113.925
288.232
57.918
155.35
447.056
77.224
Impact energy at failure
(N-m)
828.552
588.323
135.142
828.552
541.117
183.407
217.495
294.116
231.672
238.208
164.704
86.877
828.555
588.232
202.7132
517.845
470.585
231.67
The blocks GASM1,GASM2,GSM in which granite powder is added shows an impact
resistance of 828 N-m.
The block SM in which granite powder is not added shows an impact resistance of 517
N-m .
Hence the blocks which consists of granite powder shows impact resistance 311 N-m
more than that of blocks without granite powder.So the addition of granite powder to the
soil cement mix increases the impact resistance of the soil stabilized block.
Sorptivity test
The sorptivity can be determined by the measurement of the capillary rise absorption
rate on reasonably homogeneous material. Sorptivity (S) is a material property which
characterizes the tendency of a porous material to absorb and transmit water by capillarity. It
gains importance knowing the amount of water lost from the mortar.
I = S t 1/2=> S= I / t 1/2
The sorptivity values at different time intervals are tabulated in Table 9.6
Table 6
Time interval (min)
0
1
3
4
6
7
9
1
1
1
1


0
2
3
5
5
0
5
0
5
0
5
0
5
0
B l o
GASM 1
0
0.69298
0.58607
0.53345
0.50272
0.48002
0.46040
0.44676
0.43713
0.43025
0.42103
c k
GASM 2
0
0.69306
0.58615
0.53351
0.50280
0.48011
0.46047
0.44685
0.43721
0.43033
0.42114
d e s
GASM 3
0
0.78818
0.64381
0.57274
0.53678
0.51049
0.49375
0.47767
0.46604
0.45751
0.45122
i
g n
GASM 4
0
1.25022
1.02818
0.91796
0.85613
0.81436
0.77115
0.73449
0.70627
0.68400
0.66179
a
t
G S M
0
0.46204
0.40358
0.38444
0.37370
0.36464
0.36615
0.35954
0.38008
0.35332
0.35668
i
o
n
M
S
0
1.03279
0.91287
0.84735
0.81536
0.78398
0.77669
0.74990
0.73990
0.72476
0.70906
The block GSM in which only granite powder is added to the soil cement mix shows least
sorptivity when compared to other blocks .
Hence by the addition of granite powder increases the sortivity resistance of the soil
stabilized blocks.
Scope for future work
 The durability of the bricks can be improved by proper edge protection.
 Lining at the joints can be provided to fill mortor paste after wall construction.
 Other additives can be used which improves the strength of the interlocking blocks.
 For the designed interlocking system different sizes of the bricks can be
manufactured.
 Concrete blocks can also be manufactured for the same interlocking system.
 Reinforced masonry wall can be constructed by manufacturing suitable interlocking
system with hollow opening at the centre.