A PROJECT REPORT

Submitted by

AJESIMI Eric (REG. NO: GS20111402)
&
BIZIMENYERA Theoneste (REG. NO: GS20111358)

Under the Guidance of
Dr. G. Senthil KUMARAN

Submitted in partial fulfillment of the requirements for the award of

BACHELOR OF SCIENCE DEGREE IN CIVIL ENGINEERING







DEPARTMENT OF CIVIL ENGINEERING AND ENVIRONMENTAL TECHNOLOGY
SCHOOL OF ENGINEERING
(Nyarugenge Campus)
COLLEGE OF SCIENCE AND TECHNOLOGY
P.O. Box: 3900 Kigali, Rwanda.

MAY 2014
PROJECT ID: CEET/CE/2013-14/03

STRENGTH ANALYSIS OF INTERLOCKING BUILDING BLOCKS WITH
QUARRY DUST AND POZZOLANIC MATERIALS
i






COLLEGE OF SCIENCE AND TECHNOLOGY
SCHOOL OF ENGINEERING
(Nyarugenge Campus)
P.O. Box: 3900 Kigali, Rwanda.


DEPARTMENT OF

CIVIL ENGINEERING AND ENVIRONMENTAL TECHNOLOGY



CERTIFICATE

This is to certify that the Project Work entitle STRENGTH ANALYSIS OF
INTERLOCKING BUILDING BLOCKS WITH QUARRY DUST AND POZZOLANIC
MATERIALS is a record of original bonafide work, done by AJESIMI Eric (REG. NO:
20111402) and BIZIMENYERA Theoneste (REG. NO: GS20111358) in a partial fulfillment of
the requirements for the award of Bachelor of Science Degree in Civil Engineering of College of
Science and Technology under the University of Rwanda during the Academic Year 2013-2014.



. .
SUPERVISOR HEAD OF DEPARTMENT
Dr. G. Senthil KUMARAN Dr. G. Senthil KUMARAN


Submitted for the final Project Defense Examination held at School of Engineering (Nyarugenge
Campus), College of Science and Technology, on 26/May /2014
ii

DECLARATION
We, AJESIMI Eric and BIZIMENYERA Theoneste, declare that this work entitled
STRENGTH ANALYSIS OF INTERLOCKING BUILDING BLOCKS WITH QUARRY
DUST AND POZZOLANIC MATERIALS is our own research and it has never been
presented or submitted elsewhere for any degree award at any university or high learning
institution. All sources we used and quoted have been acknowledged as complete references.



.
AJESIMI Eric BIZIMENYERA Theoneste
REG.NO: GS20111402 REG.NO: GS20111358

Date: 26 /May/ 2014 Date: 26 /May/ 2014








iii

DEDICATION
AJESIMI Eric:
This research project is dedicated to:
Almighty GOD that I owe everything,
My Lord JESUS,
My family, friends and Colleagues.
Jean Luc MBARUSHIMANA
ATACO FREIGHT SERVICES Ltd staff

BIZIMENYERA Theoneste
Almighty GOD and my Lord JESUS.
My beloved parents,
My beloved family, friends and colleagues.








iv

ACKNOWLEDGEMENT
First of all, we would like to thank our almighty God who has enabled us to be where we are and
protecting us through the whole studying period.
Our sincere thanks and appreciation go to our supervisor Dr.G. SENTHIL KUMARAN for his
guidance in the whole project.
We are grateful to thank the government of Rwanda for all its efforts to provide us with security
and conductive environment in which to study.
The administration of UR (University of Rwanda) as well as of CST (College of science and
technology) deserves special thanks for all the work they do to ensure that our study at CST is a
memorable one.
To all lectures in Department of Civil Engineering and environment Technology (CEET), we say
well done! Your work deserves special recognition.
We would like also to express our sincere gratitude and thanks to those who, at different places
and various times, have helped us in this research report to become success.
Many thanks to each one who is directly or indirectly his/her assistance and advices helped us to
successfully complete this project.








v

ABSTRACT
This project was carried out to investigate the strength properties of blocks made from quarry dust
and pozzolanic materials so that they can be used as alternative material in building construction
industry. The main test of crushing of block samples was carried out at IPRC Kigali structural
engineering laboratory. Many other tests such as sieve analysis, water content determination and
chemical test for pozzolana were carried out in different CST laboratories. Two different samples
of quarry dust were used; one from STABAG stone crusher and the other one from MUSANZE
district, also the sample of pozzolana from MUSANZE district. The results indicated that
pozzolana and quarry dust samples selected are relatively suitable for block making by additional
of stabilizers such as lime or clay. The moulded block has dimensions of 30cmx15cmx12cm with
two 50% cavities of the block volume; the mixing proportion that gives the best compressive
strength is 1:1:2 (lime/clay: pozzolana: quarry dust). Results indicated that the more content of
quarry dust in the mixture, less will be the compression strength. The best compressive strength of
the samples was found on 14
th
day. The results obtained from compression strength test indicates
that blocks made with pozzolana and quarry dust from STRABAG stone crusher (PQs) gives a
compressive strength of 0.2925 N/mm
2
while the one of quarry dust from MUSANZE district(
QPm) gives 0.2750 N/mm
2
. When the block is stabilized with lime (LPQs), it gives the maximum
compressive strength of 0.7225 N/mm
2
and when stabilized with clay (CPQs) gives 0.8350
N/mm
2
which is the best compression strength of the project .Crushing of blocks discovered that
the compressive strength obtained are below from the value recommended by international
standard, state that the compressive strength of masonry blocks to be used in building
construction shall not be less than 2.5 N/mm
2.
.So the block should be rejected and further
researches are recommended by using other stabilizers for improving the compression strength.
vi

TABLE OF CONTENT
DECLARATION ....................................................................................................................... II
DEDICATION ......................................................................................................................... III
ACKNOWLEDGEMENT ........................................................................................................ IV
ABSTRACT .............................................................................................................................. V
TABLE OF CONTENT............................................................................................................ VI
LIST OF FIGURES .................................................................................................................. XI
LIST OF ABBREVIATIONS AND ACRONYMS .................................................................. XII
CHAPTER 1 .............................................................................................................................. 1
GENERAL INTRODUCTION ................................................................................................... 1
1.1 BACKGROUND .............................................................................................................. 1
1.2 PROBLEM STATEMENT ................................................................................................ 2
1.3 OBJECTIVE OF THE RESEARCH .................................................................................. 3
1.3.1 Main objective ............................................................................................................ 3
1.3.2 Specific objectives ...................................................................................................... 3
1.4 HYPOTHESIS .................................................................................................................. 3
1.5 SCOPE OF THE PROJECT ............................................................................................... 3
1.6 METHODOLOGY ............................................................................................................ 4
1.7 SIGNIFICANCE AND RATIONALE ............................................................................... 4
1.7.1 General Significance ................................................................................................... 4
1.7.2 Academic Significance ............................................................................................... 5
1.7.3 Public and administrative significance ........................................................................ 5
1.8 RESEARCH JUSTIFICATION ......................................................................................... 5
CHAPITER 2 ............................................................................................................................. 6
LITTERATURE REVIEW ......................................................................................................... 6
2.1 INTRODUCTION............................................................................................................. 6
2.2 QUARRY DUST............................................................................................................... 6
2.2.1 Introductive definition ................................................................................................ 6
vii

2.2.2 Evaluation of quarry dust ............................................................................................ 9
2.2.3 Sieve analysis for quarry dust. .................................................................................. 10
2.2.4 Application of quarry dust ........................................................................................ 10
2.3 POZZOLANA MATERIALS .......................................................................................... 11
2.3.1 Introduction .............................................................................................................. 11
2.3.2 Classification ............................................................................................................ 11
2.3.3 The activity of pozzolana. ......................................................................................... 12
2.3.4 Selection of quarry dust and pozzolanic materials for stabilization ............................ 13
2.4 INTERLOCKING BLOCKS ........................................................................................... 13
2.4.1 Introduction .............................................................................................................. 13
2.4.2 Interlocking mortarless blocks for building construction ........................................... 16
2.4.3 Interlocking Hollow-blocks ...................................................................................... 18
2.4.4 Thai interlock blocks ................................................................................................ 19
2.4.5 Solbric system from South Africa ............................................................................. 20
2.4.6 Hydraform system from South Africa ....................................................................... 22
2.4.7 Bamba system from South Africa ............................................................................. 23
2.4.8Auram system from India .......................................................................................... 24
2.4.9 Tanzanian interlock brick (TIB) system .................................................................... 25
2.5 STRENGTH ANALYSIS OF BLOCKS .......................................................................... 25
2.5.1 Testing for compressive strength .............................................................................. 26
2.5.2 Compressive strength and other mechanical properties ............................................. 26
2.5.3 Factors affecting compressive strength ..................................................................... 27
2.6 HYDRAFORM MACHINE DESCRIPTION................................................................... 27
2.6.1 Introduction .............................................................................................................. 27
2.6.2 Types of hydraform machine .................................................................................... 27
2.7 ADVANTAGES AND SOME LIMITATIONS OF IBBS ................................................. 29
2.7.1 Advantages of IBBs with quarry dust and pozzolanic materials ................................ 29
2.7.2 Limitations of IBBs with quarry dust and pozzolanic materials ................................. 29
2.8 GENERAL ADVANTAGES AND DISADVANTAGES OF IBB SYSTEM.................... 30
2.8.1 Advantages ............................................................................................................... 30
2.8.2 Disadvantages........................................................................................................... 30
viii

CHAPITER 3 ........................................................................................................................... 32
RESEARCH METHODOLOGY .............................................................................................. 32
3.1 INTRODUCTION........................................................................................................... 32
3.2 TESTING OF POZZOLANS FROM MUSANZE DISTRICT .......................................... 32
3.2.1 Sieve analysis ......................................................................................................... 32
3.2.2 Sieve Equipment ....................................................................................................... 33
3.2.3 Sieve analysis procedure ........................................................................................... 33
3.2.4 Particle properties ..................................................................................................... 35
3.2.5 Mechanical tests of pozzolans ................................................................................... 35
3.2.6 Chemical test of pozzolans ....................................................................................... 36
3.2.7 Reaction conditions .................................................................................................. 36
3.2.8 Chemical laboratory equipment ................................................................................ 37
3.2.9 Chemical test procedure for pozzolan sample from G.L.C (Musanze District)........... 38
3.2.10 Water content determination for pozzolana sample ................................................. 40
3.2.11 Summary for pozzolan tests .................................................................................... 42
3.2.12 Lime for pozzolans stabilization ............................................................................. 43
3.2.13 Clay occurrence ...................................................................................................... 45
3.2.14 Clay for Stabilization .............................................................................................. 45
3.2.15 Chemical composition of clay ................................................................................. 46
SOURCE: WWW.SIENCEDIRECT.COM ........................................................................................ 46
3.3QUARRY DUST FROM STRABAG STONE CRUSHER ............................................... 46
3.3.1 Sieve analysis ........................................................................................................... 46
3.3.2 Water content in quarry dust sample from STRABAG stone crusher ........................ 48
3.4 QUARRY DUST FROM MUSANZE DISTRICT ........................................................... 49
3.4.1 Sieve analysis ........................................................................................................... 49
3.4.2 Moisture (water) content for quarry dust from MUSANZE district ........................... 51
3.5 COMPARISON IN WATER CONTENT FOR THE TWO QUARRY DUST ................... 52
3.6 PRODUCTION OF INTERLOCKING BUILDING BLOCKS ........................................ 52
3.6.1 Introduction .............................................................................................................. 52
3.6.3 Block production procedures .................................................................................... 53
3.6.4 Hydraform machine blocks product .......................................................................... 54
ix

CHAPITER 4 ........................................................................................................................... 56
RESULTS AND DISCUSSION ............................................................................................... 56
4.1 PRESENTATION OF RESULTS .................................................................................... 56
4.1.1 Introduction .............................................................................................................. 56
4.1.2 Hypothesis ................................................................................................................ 56
4.1.3 Testing procedures and calculations .......................................................................... 56
4.1.4 Purpose of crushing strength test............................................................................... 57
4.1.5 Equipments ............................................................................................................... 57
4.1.6 Block dimensioning .................................................................................................. 57
4.1.7Area and volume calculations .................................................................................... 58
4.1.8 Results for sample mixing of pozzolan and quarry dust from STRABAG (PQs) ....... 59
4.1.9 Results for sample mixing of pozzolana and quarry dust from MUSANZE (PQm) ... 60
4.1.10 Results for sample mixing of Lime; pozzolana and quarry dust from STRABAG
(LPQs) .............................................................................................................................. 61
4.1.11 Results for sample mixing of Clay; pozzolana and quarry dust from STRABAG
(CPQs) .............................................................................................................................. 62
4.2 ANALYSIS OF RESULTS ............................................................................................. 63
4.2.1 Variability of compressive strength ........................................................................... 64
4.2.2 Comparison in strength between project blocks with other types of block ................. 65
Source: Ruliba clays ltd; NPD Cotraco .............................................................................. 65
4.2.3 General comparison of blocks ................................................................................... 65
4.2.4 Checking of hypothesis ........................................................................................... 66
CHAPITER 5 ........................................................................................................................... 67
CONCLUSION AND RECOMMENDATIONS....................................................................... 67
5.1 CONCLUSION .......................................................................................................... 67
5.2 RECOMMENDATION .............................................................................................. 68
REFERENCES......................................................................................................................... 70
APPENDICES ......................................................................................................................... 72

x

LIST OF TABLES
Table 2. 1: Common rocks with their mineral composition [8] ...................................................... 9
Table 2. 2: Review of performance Studies (source: Anand and Ramamurthy) [12] .................... 14
Table 2. 3: Categories of interlock block systems [12] .............................................................. 17
Table 3. 1: Sieve analysis results of Pozzolans from Musanze District ........................................ 34
Table 3. 2: Values multiplied with titrated compounds ............................................................... 39
Table 3. 3: Chemical test results of Pozzolans sample (0.5 grams). ............................................. 39
Table 3. 4: Percentage in moisture content .................................................................................. 41
Table 3. 5: Chemical composition of clay [18]............................................................................ 46
Table 3. 6: Sieve analysis results for quarry dust from STRABAG stone crusher ........................ 46
Table 3. 7: Sieve analysis curve for quarry dust from STRABAG stone crusher ......................... 47
Table 3. 8: Water content in percentage for quarry dust from STRABAG ................................... 48
Table 3. 9: Average water content in 100grams of STRABAG quarry dust sample ..................... 49
Table 3. 10: Sieves analysis results for quarry dust from MUSANZE district ............................. 49
Table 3. 11: Moisture (water) content results for quarry dust from MUSANZE district ............... 51
Table 4. 1: Strength of block 7 days after molding (PQs) ............................................................ 59
Table 4. 2: Strength of blocks 14 days after molding (PQs) ........................................................ 60
Table 4. 3: Strength of blocks 7 days after molding (PQm) ......................................................... 60
Table 4. 4: Strength of blocks 14 days after molding (PQm) ....................................................... 61
Table 4. 5: Strength of block 7 days after molding (LPQs).......................................................... 61
Table 4. 6: Strength of block 14 days after molding (LPQs)........................................................ 62
Table 4. 7: Strength of block 7 days after molding (CPQs) ......................................................... 62
Table 4. 8: Strength of block 14 days after molding (CPQs) ....................................................... 63
Table 4. 9: Block comparison with other types existing in Rwanda ............................................. 65
Table 4. 10: General comparison of blocks ................................................................................. 65
xi

LIST OF FIGURES
Figure 2. 1: Quarry dust samples. ................................................................................................. 7
Figure 2. 2: Examples of interlocking hollow blocks made by Ruliba clays ................................ 13
Figure 2. 3: Example of masonry wall with interlocking mortarless blocks ................................. 19
Figure 2. 4: SOLBRIC interlock brick [12] ................................................................................. 21
Figure 2. 5: Hydraform machine ................................................................................................. 22
Figure 2. 6: The use of Bamba interlocking brick units in stretcher bond. ................................... 23
Figure 2. 7: Auram Interlocking Block [14] ................................................................................ 24
Figure 2. 8: Compressive Strength Testing Machine ................................................................... 26
Figure 3. 1: Sieve analysis equipment (ASTM. 422 Standard test Method) ................................. 33
Figure 3. 2: Sieve analysis curve for pozzolans from Musanze District. ...................................... 35
Figure 3. 3: Chemical testing with a tutorial assistant ................................................................. 37
Figure 3. 4: Used CST chemical laboratory equipment ............................................................... 37
Figure 3. 5: Graphical representation of chemical test results ...................................................... 40
Figure 3. 6: Equipment for determination of water (moisture) content ........................................ 41
Figure 3. 7: Average water content in 100grams of a pozzolan sample ....................................... 42
Figure 3. 8: Fine particles passing in percentage ......................................................................... 50
Figure 3. 9: Average water content in 100grams of a quarry dust sample .................................... 52
Figure 3. 10: Used hydraform machine for making blocks .......................................................... 55
Figure 4. 1:Crushing of block equipment .................................................................................... 57
Figure 4. 2: Hollow block dimensioning ..................................................................................... 58
Figure 4. 3: Presentation of obtained compressive strength results .............................................. 64
xii

LIST OF ABBREVIATIONS AND ACRONYMS
ASTM: American Standard Testing Materials
BS: British Standard
CE: Civil Engineering
CEET: Civil Engineering and Environment Technology
CST: College of science and Technology
CPQs: Clay, Pozzolana, Quarry dust from Strabag
GBFS: Granulated Blast Furnace Slag
GLC: Great Lakes Cement
g: gram
GBFS: Granulated Blast Furnace Slag.
HSD-AIT: Human Settlements Division of the Asian Institute of Technology
IBBs: Interlocking Building Blocks
IBs: Interlocking Blocks
IPRC/ Kigali : Integrated Polytechnic Regional Center/Kigali
IS: Indian Standard
IS: International standard
LPQs : Lime, Pozzolana, Quarry dust from Strabag
Mm: Millimeter
MPa: Mega-Pascal
PQs : Pozzolana, Quarry dust from Strabag
PQm : Pozzolana, Quarry dust from Musanze district
PFA: Pulverized Fuel Ash
PGCHS: Post-Graduate Centre Human Settlements
TIB: Tanzanian Interlock Brick
TISTR: Thailand Institute of Scientific and Technological Research
UR: University of Rwanda
UR-CST: University of Rwanda- College of Science and Technology
USA: United States of America

1

CHAPTER 1
GENERAL INTRODUCTION
1.1 BACKGROUND
The cost of construction materials in Rwanda is being increased at a high rate because of higher
consumption of building materials due to country development. Concrete blocks which are most
popular building material in the world, requires a great consumption of energy. River sand has
been the most popular choice for the aggregate component of concrete in the past, but overuse of
the material has led to environment concerns, the depleting of securable river sand deposits and a
concomitant price increase in the material. Therefore; there is a need to find new and more costly
saving materials with sufficient strength and durability so as to maintain the cost of constructing
houses at prices affordable to clients. The potential for using pozzolanic materials and quarry dust
as alternatives materials which can substitutes cement and river sand was considered here and
used as raw materials for making building blocks in construction sector. Natural sand takes
millions of years to form and it is not replenishable. In such a situation the quarry dust and
pozzolanic materials can be economical alternative materials to the river sand and cement. Thus,
this research was focused on how quarry dust and pozzolanic materials can be used to make
buildings interlocking blocks of sufficient strength and durability. Using quarry dust will lead to
the conservation of natural resources and preservation of environment which are the essence of
any country development. Many studies on the usage of quarry dust and pozzolanic materials will
be carried out to judge the properties of blocks and strength behavior. Quarry dust has been
proposed as an alternative to river sand that gives additional benefit to concrete. Quarry dust is
known to increase the strength of concrete over concrete made with equal quantities of river sand,
but it causes a reduction in the workability of concrete. [1]
When examining the quality of pozzolana and quarry dust it becomes apparent that if both are
used together, the loss in early strength due to one may be alleviated by the gain in strength due to
the other, and the loss of workability due to the one may be partially negated by the improvement
in workability caused by the inclusion of the other. [2]
2

This work is aimed to determine whether the concurrent use of the two by-products will lead to a
range of economic and environment benefits and if such benefits could be obtained by the use of
these two materials together to produce an interlocking block with sufficient strength. [3]
1.2 PROBLEM STATEMENT
Due to rising cost of construction materials and the need to adhere to sustainability, alternative
construction techniques and materials are being sought. Different materials such as earth, cement,
and sand have been used worldwide since thousands of years to produce building block or brick
according to local climate and environment as well as local traditions customs. Hills are being
destroyed to get construction materials therefore how we can develop new building blocks from
the remaining quarry dust with pozzolanic materials for solving this environment problem. But
we still struggling for modernity where our construction need aesthetic, durability and
sustainability, environmental and economic materials of exchange, instead of using costly
concrete block that all peoples cant access. Is there any engineering material that can play similar
role? Also, as we are heading to development we cannot step backward to the use of old mud
block which are cheap but neither aesthetic nor high compression strength resistance. Briefly,
how to develop it and at the same time assess sufficient strength and still environment and
economical friendly? These are challenges that will be concerning this project. That is why it will
be necessary to assess if the quarry dust and pozzolanic material can be used as alternative
materials in making building blocks for the safety of environment and at low cost by using more
available and local natural materials.
The following are some related problems:
There is a rising in cost of existing construction materials (clay, sand, Cement).
Existing durable materials with sufficient strength are expensive.
Destruction of environment for getting natural construction materials (clays, sand).
Concrete blocks are expensive and all peoples cant access to them.
Mud block/ brick consume a lot of energy while firing them.
Mud block / brick which currently used in rural areas have neither strength nor aesthetics.
3

1.3 OBJECTIVE OF THE RESEARCH
1.3.1 Main objective
The main objective of this project is to analyze or assessing the strength of interlocking building
block made with quarry dust and pozzolanic materials in order to control its quality and/or their
mechanical properties.
1.3.2 Specific objectives
Find out the chemical components of pozzolanic materials as well as of quarry dust.
To determine the suitable mixing ratio between quarry dust and pozzolanic materials to be used
when moulding of blocks in order to get the maximum strength.
Moulding block samples made from quarry dust and pozzolanic materials.
Testing the compressive strength of the moulded interlocking blocks.
Conducting a comparative strength study between other types of existing building blocks from
different types of materials and the best one moulded.
To draw some conclusions and recommendation about safety of this new material in building
construction industry.
1.4 HYPOTHESIS
Structural wall must withstand and resist against natural and artificial action like compressive
stress, capillarity, etc. This will depend on resistance of structural materials that were used to
build that wall; materials here are blocks made with quarry dust and pozzolanic materials with an
addition of lime/clay for accurate stabilization. The test of crushing strength of the product was
made to know the ability of the block to support the applied loads in order to make safe design.
1.5 SCOPE OF THE PROJECT
To evaluate the properties of an interlocking block requires many laboratory tests that can prevent
other necessary works and test to be performed due to the time limitation some other test was not
carried out. Data was collected from different regions of Rwanda particularly in north province
and samples were tested at IPRC Kigali in structural engineering laboratory and in University of
Rwanda (CST) laboratories.
4

This research does not deal with other types of strength analysis such as shear strength.
Some standards are not followed for instance the required dimensions for block will be used if
necessary to identify the proposed block from others.
Our case study: Rwanda
1.6 METHODOLOGY
Different methods have been used during execution of this project, while collecting necessary
data; strength analysis, blocks production procedures and laboratory tests for block materials.
Collection of stone quarry dust from different area of Rwanda in order to justify which types of
rock present the best materials for block production.
Documentation through books and browsing on the internet for getting enough theoretical
information relevant to the topic.
Using laboratory tools for determining compressive strength of moulded block samples.
Undertaking site visit to different quarries in Rwanda for collecting block materials.
Data analysis and interpretation of all results obtained from laboratory test of block samples.
Conducting a comparative strength study between the existing building blocks and the block
molded.
According to the obtained results, some conclusions and recommendations were drawn.
1.7 SIGNIFICANCE AND RATIONALE
1.7.1 General Significance
This research aims to create a new building material in construction industry and analyze its
strength. Thus, entrepreneurs related to buildings industry will aware on other alternative
construction materials by using available nature materials in Rwanda like stone quarry dust and
pozzolanic materials with effective-cost and durability , also with reduction of environment
pollution from stones quarrying.
As, the expected results are achieved, the use of quarry dust and pozzolanic materials should be
promoted if it is cost saving and having adequate strength.
5

1.7.2 Academic Significance
For the academic purpose, this research project will be used by engineering students during their
studies and/or research. Scientifically, this research will be used for further research on building
construction materials in developing the country like Rwanda without environment pollution.
1.7.3 Public and administrative significance
This project is one of the project conducted about strength analysis of quarry dust and pozzolanic
materials; thus researchers may using it as a reference document for some tests already carried out
during it execution.
1.8 RESEARCH JUSTIFICATION
This project research will be helpful in building construction and other type of structures. Blocks
will be moulded from stone quarry dust which was normally considered as waste and pozzolanic
materials, then analyzed by different test such as compression strength; chemical test, For the
purpose of promoting the usage of available materials which are locally present in Rwanda.
Reducing the usage of sand which causing the depletion of securable river sand deposits and the
cement which is expensive and consuming energy while manufacturing. As the expected results
will be achieved, the use of quarry dust and pozzolanic materials will be promoted where there
will be saving in money and also the environment will be also protected against erosion where
sand and cement are no longer the only materials to be considered for making building blocks.


6

CHAPITER 2
LITTERATURE REVIEW
2.1 INTRODUCTION
This chapter provides detailed information that pertains to this research project, and this
information will be obtained from various sources such as books, internet. Only credible sources
of information will be consulted. It is also talking about quarry dust, Pozzolanic materials,
interlocking blocks and strength analysis. The quality and cost effectiveness of construction
materials employed in housing development are among the major factors that determines the
optimal delivery of housing projects in Rwanda. Therefore, materials that can be used for building
construction must provide some objective evidence of quality and cost effectiveness in terms of
functional requirement and low income economy respectively. In view of this, the search for low-
cost material that is socially acceptable and economically available, at an acceptable quantity
within the reach of an ordinary man becomes a subject of continuous interest. The belief that the
African region is full of raw materials suitable for local uses encourages this, the construction
sector is not making optimal use of them. [4] The most significant element of house in housing
development is the wall which is a component of many constituent materials. In most villages,
mud and clay materials are still being used for wall making with their acceptability as last
alternative for the poor but, with some level of quantity attendant problem [5], especially in an
area of high flooding potential. Hence, many of such houses are deprived of their social
acceptability. In every quarry site in the country, the dust produced is most often handled as
waste.
2.2 QUARRY DUST
2.2.1 Introductive definition
The quarry dust is the by-product which is formed in the processing of the granite stones which
broken downs into the coarse aggregates of different sizes. Researchers have been conducted in
different parts of the world, to study the effects of incorporation of quarry dust into block making.
Quarries are operating in many parts in our country to supply coarse aggregates for various types
of construction. This influence the increase in production of quarry dusts in our country which is
7

considered as waste material. Their properties mainly depend on the properties of the parent rock
such as chemical and mineralogical composition.

Figure 2. 1: Quarry dust samples.
Agdebe and Joel (in 2004).Described quarry dust as cohesion-less sandy material acquired either
naturally (which is rare) or artificially by the mechanical disturbance of parents rocks (blasting of
rocks) for construction purposes, composed largely of particles with a diameter range of
0.05mm.They found in their study on suitability of quarry dust as partial replacement of sand in
hollow block production that quarry dust is cheaper than river sand during rainy season [6].
A.Sivakumar and Prakash M. (October 2011). In the recent past good attempts have been
made for the successful utilization of various industry by products( such as fly ash, silica fume,
rice husk ash, foundry waste) to save environment pollution. Quarry dust, a by-product from the
crushing process during quarrying activities is one of the materials that have recently gained
attentions to be used as concreting aggregates [7].
The basic tests on quarry dust as per IS-383-1987 and its specific gravity was around 1.95 Wet
sieving of quarry dust trough a 90 micron sieve was found to be 78% and the corresponding
bulking value of quarry dust was 34.13%. Researchers have been conducted in different parts of
the world, to study the effects of incorporation of quarry dust into concrete.
Crushed granite coarse aggregate conforming to IS 383-1987 of size 12 mm and down having a
specific gravity of 2.6 was used. The loose and compacted bulk density values of coarse aggregate
were 1483 and 1680 kg/m
3
, respectively, for different grade of concrete.
8

Galetakis and Raka (2004) studied the influence of varying replacement proportion of sand with
quarry dust (20, 30 and 40%) on the properties of concrete in both fresh and hardened state. The
analysis of experiment data showed that the addition of the quarry dust improved the strength
properties of concrete which was on part with that of conventional concrete, Thus Quarry dust
may be used as an effective replacement material for natural river sand in block making. [7]
Varghese (2008) recognizes granite material from which quarry dust is generated as an igneous
rock. It is being formed by tectonic activities of volcanic eruption, ejecting up to the terrestrial or
the outer crust some molten magma that later solidify into igneous rocks [8]. This deposit is
usually used for concrete of high compressive strength in the construction industry. There is no
significant chemical change in its production is very good for walling units. This production
would help to increase the availability of local building materials and in turn would influence
positively the cost of housing development in Rwanda.
Ilangovana et al,( in 2008) studied the strength and durability properties of concrete containing
quarry dust as fine aggregate and found that the compressive, flexural strength and durability
studies of concrete made with quarry rock dust were nearly 10% more than the conventional
concrete. Their workability results showed slump values ranging between 60-90 mm and
compacting factor 0.87 0.90 for grade 20 concrete. The range of 20 days compressive and
flexural strength for grade 20 concrete were found to be 23.7 34.50 N/mm
2
and 3.45 6.40
Physically, quarry dust has smooth, long, angles, sharp at corner and grey in colour.
The Surface of quarry dust is rougher than sand. Theoretically, the rough surface will lead to high
bind compared to smooth surface. The fineness of quarry dust is defined as particles that retained
using 4.75mm, 2.36mm, 1.18 mm, 0.6mm, 0.3mm and 0.15mm and 0.75 sieves. Based on
ASTM C 136-84.Picrometer has been used to determine the specific gravity of quarry dust.
Based on ASTM C 128-88, specific gravity of quarry dust is 2.65 where it can be
categorized as fine aggregates. Besides, water absorption of dry surface of quarry dust has to be
analyzed. Quarry dust is being dried in oven for 24 hours at 105C. Percentage different between
wet and dry dust is divided by density before dried to get the value of water absorption which is
0.6%. respectively. [9]
9

2.2.2 Evaluation of quarry dust
Different engineering studies have been conducted for identifying the suitability of quarry dust
uses. Various rock types produce different types or different qualities of quarry dust due to the
inclusion of their fresh minerals. Properties of quarry dust mainly depend on the properties of the
parent rock such as chemical and mineralogical composition, physical and chemical stability,
petrographic characteristics, specific gravity, hardness, strength, pore structures and colour.
As far as quarry dust quality is concerned, the most important property is the mineralogical
composition. [10]
Table 2. 1: Common rocks with their mineral composition [8]

S/N ROCK TYPE MINERAL COMPOSITION
1 Biotite gneiss Quartzite, feldspar, biotite
2 Migmatitic gneiss and
Migmatitic
Quartzite ,feldspar, biotite, hornblende
3 Hornblende biotite gneiss Quartzite ,feldspar, biotite, hornblende
4 Granite gneiss Quartzite ,feldspar, biotite,
5 Chamoctic gneiss Quartzite ,feldspar, biotite,
6 Chamoctic Quartzite ,feldspar, biotite, hornblende
The most common minerals in these rocks are quartz, feldspar, hornblende, biotite and
hyperthenes according to different research.
The analysis of experimental data showed that the addition of quarry dust improved the strength
properties of blocks. From testing results, it is inferred that the quarry dust may be used as an
effective replacement of material for natural sand. This project consists of analyzing the strength
of interlocking building blocks with quarry dust and pozzolanic materials.
10

2.2.3 Sieve analysis for quarry dust.
The process of dividing a sample of aggregates into various fractions, each consisting of particles
of same nominal size. The resultant of particle size distribution is called the gradation. It
determines the quantity and percentage of the constituent particles in the samples as well as their
grading distributions.
2.2.4 Application of quarry dust
There are many applications of quarry dust such as in construction, processing, landscaping, and
recreational and agriculture
a. Application of quarry dust in construction
In construction industry, quarry dust is used as an aggregate substitute especially in concrete
mixture. The application of quarry dust can reduce cost of construction. Through the research it
was proved that using quarry dust is cheaper than sand. Quarry dust also is used in construction of
sub base in highway.
b. Application of quarry dust in processing
In India, quarry dust is a material used to produce concrete block as well as interlocking block. It
was mixed with chalk and gypsum to block. The use of quarry dust in producing block is also
applied in South Africa. Besides that, quarry dust is used to produce tiles.
c. Application of quarry dust in landscaping and recreational
United State of America, Australia and New Zealand have applied the use of quarry dust for
landscaping. For recreational use, quarry dust is used as fertilizer for planting and as walkways.
d. Application of quarry dust in agriculture
Quarry dust is act as fertilizer where it contains nutrients that are good for plants. A research has
been conducted by University of Massachusetts found that there are four (4)types of plants that
can use quarry dust as fertilizer, salad, tomatoes, apple and corn.
11

2.3 POZZOLANA MATERIALS
2.3.1 Introduction
Pozzolans are materials that contain reactive silica and alumina, which when finely ground and
added to lime, impart a hydraulic property to the binder. Pozzolans take their name from the town
of pozzouli in Italy where the local volcanic ash and derived clays were found by the romans to
produce a binder that is harder than air lime, and which was found to set under water. The generic
name pozzolan is now applied to any reactive material which imparts these properties to a lime,
and includes brick dust, ground tile/ pottery, pulverized fuel Ash (PFA), granulated blast furnace
slag (GBFS) and some processed clays (metakaolin), plus other similar furnace slag, plus other
similar materials. The one thing they all have in common is that they have been exposed to higher
temperature which has resulted in the alteration of the materials components such that the silicates
and aluminates present become reactive in the presence of hydrated lime.
S.K Duggal (2008). Defines pozzolan as a siliceous material which whilst itself possessing no
cementitious properties, either processed or unprocessed and in finely divided form, reacts in the
presence of water with lime at normal temperatures to form compounds of low solubility having
cementitious properties. [10]
Pozzolan may be natural or artificial, fly ash being the best known in the latter category. Before
the advent of cement these were used with lime to make concrete. The main justification for
using pozzolan is the possibility of reducing costs of construction materials. If they are to reduce
costs, they must be obtained locally and it is for this reason that they have not so far been much in
use.
2.3.2 Classification
Pozzolans are classified as natural and artificial.
a) Natural Pozzolans
All Pozzolans rich in silica and alumina and contain only a small quantity of alkalis. Some of the
naturally occurring Pozzolans:
1. Clays and shales which must be calcined to become active.
12

2. Diatomaceous earth and opalite cherts and shales which may not need calcinations (most active).
3. Volcanic tuffs and pumicites; fine grained ashes form better pozzolan. However, tuffs- solidified
volcanic ash may be ground to desired fineness for use.
4. Rhenish and Bavarian trass.
b) Artificial pozzolan:
Some of the examples of artificial Pozzolans are:
1. Fly ash.
2. Ground blast-furnace slag.
3. Silica fume
4. Surkhi
5. Rice hust ash.
2.3.3 The activity of pozzolana.
When it is mixed with ordinary Portland cement the silica of the pozzolana combines with the
free lime released during the hydration of cement. This action is called pozzolanic action. The
pozzolanic activity is due to the presence of finely divided glassy silica and lime which produces
calcium silicate hydrate similar to as produced during hydration of Portland cement. The silica in
pozzolana reacts with the lime produced during hydration of Portland cement and contributes to
development of strength. Slowly and gradually additional calcium silicate hydrate is formed
which is a binder and fills up the space, gives impermeability, durability and ever increasing
strength. [3]
Hydration of Portland cement may be expressed as:
C
3
S + H
2
O C-S-H + Ca (OH)
2
C-
S-H: Calcium silicate Hydrate ; Ca (OH)
2
: Lime; SiO
2
: Silica
Lime produced combines with silica of pozzolana
Ca (OH)
2
+ SiO
2
C-S-H
13

2.3.4 Selection of quarry dust and pozzolanic materials for stabilization
Low quality stabilized blocks result from lack of control or monitoring of materials and the
whole production process. The field of quarry dust and pozzolanic materials selection involves
identification of the distribution large and small particles within a sample. To limit the size of
large particles and remove impurities, after being first pulverized, materials were passed through
standardized sieves according to size of particles of quarry dust and pozzolanic materials. An
important factor in materials stabilization is the quarry dust and pozzolanic materials cohesion
that depends on their fines fraction and bonding properties. Quarry dust and pozzolanic materials
selection is often conceived as once-off process of testing to confirm the materials to be used pass
the criteria for stabilization and to determine the best ratio of quarry dust and pozzolanic materials
to stabilize. However to maintain quarry dust and pozzolanic consistency, it is necessary
practically to constantly monitor the quarry dust and pozzolanic materials properties and
compensate for any changes that occur.
2.4 INTERLOCKING BLOCKS
2.4.1 Introduction
There are many types of interlocking block developed in various part of the world. For example,
Haenar blocks, the Menaco block system and Putra block (Thanoonet.al, 2002). Although various
systems were developed, the main idea of an interlocking block system is to provide a much faster
construction time. This is because interlocking block system is dry stacked and use less mortar
compared to conventional masonry construction [11]

Figure 2. 2: Examples of interlocking hollow blocks made by Ruliba clays
14

Earlier development of interlocking block was in Thailand where it was first developed to reduce
the use of timber in house construction. It was proven that with the use of interlocking block,
construction cost was reduced and also completion time was faster because the block used
mortarless compared to conventional masonry construction.
However, primary design of these block have few disadvantages. The blocks were heavy and
building construction required a certain amount of masonry skills. Also, a lot of mortar was used
for the joints thus taking longer construction time. The drawbacks were repaired with the
development of the interlocking block technique by the Human Settlements Division of the Asian
Institute of Technology (HSD-AIT), Bangkok in cooperation with Thailand Institute of Scientific
and Technological Research (TISTR) in the early 1980s.The Post-Graduate Centre Human
Settlements (PGCHS), of the Catholic University of Leuven, Belgium, in 1986-1990 has assisted
HSD-AIT and TISTR in optimizing the interlocking block technique.
The concept of interlocking blocks followed a few principles where the blocks are shaped with
projecting parts, which fit exactly into depression in the blocks placed above, such that they are
automatically aligned horizontally and vertically. Thus, block laying is possible without special
masonry skills. This dry stacked system is also why less mortar could be used and consequently
amount of cement as binding agents is saved. There were vertical holes in the block to reduce the
weight of the block and to insert steel rods for reinforcement, and/or to pour liquid mortar,
which runs through the full height of the wall, making it more stable. In order to achieve accurate
alignments of bricks placed at right angle, the length of the block was designed to be double its
width.
Table 2. 2: Review of performance Studies (source: Anand and Ramamurthy) [12]
Name of system Block type and
material
Interlocking
mechanism
Salient observations
Mechano
system,Peru
Hollow (sand-
lime)
No-interlocking
geometry- stability
only through grouting
-compressive test on
prism(20% reduction in
strength than mortar-laid
masonry)
-Diagonal tension
15

test;horizontal reinforcement
increases diagonal strength and
provides ductility
Modified H-block,
USA
Hollow(concrete) Tongue and groove in
head joint
-Axial compression tests on
hollow(average efficiency of
49%) and grouted prisms
-Higher flexural strength on
grouted specimens
Sparfil system,
Canada
Hollow(light
weight concrete)
No-geometric
interlocking used as
surface bonded
masonry
-compressive strength is
affected by individual block
strength, and surface bonding
provides flexural resistance
Haenersystem,USA
and Canada
Hollow(concrete) Projecting nibs in bed
joint: tongue and
groove head joint
-concentric and eccentric
compression and flexural tests
on grouted specimens-
compressive strength higher
than conventional masonry-
Benefits of strain gradient
effects greater
WHDBlock,USA Hollow(concrete) Dovetail arrangement
in head joint
-axial compression tests;
Hollow prisms; lower
efficiency; grouted prisms;
strength increases higher than
conventional masonry
-Increase in flexural strength
due to grouting not as
significant as conventional
masonry-Diagonal tension test
16

on reinforced grouted
specimens-improve ductility
Sparlock system,
Canada
Hollow concrete Through geometry and
stacking pattern
-Axial compression;
ungrouted; face fell cracking
close to ultimate load.
Grouted specimens;face shell
cracking well before ultimate
load due to lateral tensile
strains in grout-Lateral load
tests on hollow block wall
specimens-Finite element
analysis to predict stress
distributions in bending and
moment capacities of dry stack
assembly

Numerous literature on interlocking block are produced, however test results on behavioral
characteristics are available only for a few, as shown in Table 2.2also concluded that development
of interlocking blocks reveals that(a)may have complex shapes, which appear to have been
deliberate, and such intricacies in block geometry ( tongue and groove or undercut and dovetail
arrangement)necessitate mechanized production methods; and (b) the presence of continuity of
horizontal and vertical joints from inner to outer face [12]
2.4.2 Interlocking mortarless blocks for building construction
Interlocking blocks can be produced as solid, perforated or hollow blocks. The demarcation
between hollow and perforated blocks primarily depends on the surface area of the holes. If they
occupy less than 25 % of the surface area, they are called perforated blocks, if more we define
them as hollow blocks(BS 6073-1:1981 clause 3.3). We can characterize blocks in terms of
their solidity as follows:
17

The more solid the block the more material required and more powerful the press needed to attain
enough block density, but less binder will be needed for satisfactory block strength.
The more perforations, increasing up to 50%, the more binder will be required in the mix to
achieve the higher strength needed for thin membranes formed onto hollow block.
The two solidity characteristics of blocks above, each have extreme conditions that increase cost
of blocks. The best percentage of perforation is that which minimize some combination of weight,
material and the power requirement of the press. To reduce the cement/sand ratio in the mix for
hollow blocks, the size of perforations should be reduced.
Interlocking requires a variety of shapes/ parts to construct different wall joints. The existing
commercial interlock designs have different configurations and thus vary the number of part
blocks necessary to perform the same construction operations. Table 2.2 divides interlocking
blocks into two groups according to their locking systems.
Category A blocks have interlocks that restrict movement both horizontal and transverse to
building wall surface, Category B blocks allow horizontal movement and only limit transverse
movement during wall assembly. [12]
Interlocking blocks have three types of locking (jointing) methods; Tongue and Groove (T&G),
Protrusions and Depressions (P&D), and Topological non planar locking. The T&G and P&G
are the typical locking methods, while topological method is not a popular one.
Table 2. 3: Categories of interlock block systems [12]
Category A Both horizontal and
transversal block movements restricted
Category B Free horizontal and restricted
transversal movements
Auram Alan block
Bamba Hydraform
Haener Interlocking System Solbric
Osteomorphic
Tanzanian
18

Thai
Before involving ourselves in the descriptions of interlocking blocks, let us be acquainted with the
terms used in block work.
Block: is a masonry unit exceeding 337.5mm in length, 225mm in width or 112.5 in height. The
following definitions also apply the interlocking block arrangement.
Bat: is a piece (formed by cutting perpendicular to the face) of a brick with a reduced length.
Block: size measure equal to the length of one block
2.4.3 Interlocking Hollow-blocks
Interlocking hollow blocks are made from sand-cement that can compete with conventional
technologies in terms of quality, strength and cost. There are many promising types of interlock
blocks in Canada to mention just a few:
Alternate face-shell components figure 2.1a, known as Sparlock system Hines,(1993).
Projecting lug system components figure 2.1b, known as Haener system Gallegos,

Figure 2.1 shows Canadian interlocking hollow-blocks with general measurements of 16 x 8 x
8 (400 x 200 x 200mm) representing more than thirty existing types as discussed by Thanoon et
al. (2004), and Ramamurthy &Nambiar (2004). Most of the interlocking hollow-blocks are used
to replace formwork for casting reinforced concrete walls. The Sparlock system allows placement
only of vertical reinforcements while the Haener system provides for both horizontal and vertical
reinforcements. The normal material mix ratios (cement to sand/aggregates) for producing hollow
blocks are richer than 1:10 due to the high strength requirements of thin block webs, and to
withstand the pressure transmitted on placing concrete grout. The diagrams (Figure 2.3) illustrate
the assembly of block units and how they fit to build a wall or framework of a wall.
19


Figure 2. 3: Example of masonry wall with interlocking mortarless blocks
The popular types of interlocking block in Africa and Asia are made from stabilized soil and are
meant for low cost housing. The following designs exist in the market: Thai interlocking block;
Solbric, Hydraform and Bamba Systems from South Africa; Auram system from India and
Tanzania type.
The above listed types of interlocking blocks were invented by different people at different times
to reduce mortar costs, enhance construction productivity and building characteristics (accuracy,
stability and strength); achieved by the proper choice of production method, building/wall
construction technique and locking mechanism.
2.4.4 Thai interlock blocks
The Thai interlocking block with dimensions 300x150x100mm, was developed in the early
1980s, by the Human Settlement Division of the Asian Institute of Technology (HSD-
AIT).Bangkok, in cooperation with Thai Institute of Scientific and Technical Research
(TISTR).This is an interlocking block developed from brick. The Thai interlocking block is
produced using a modified CINVA-Ram manual press developed in Columbia in
1956(VITA1975). Vertical holes also run through the full height of a wall serving the following
purposes:
They reduce weight
20

They can house reinforcement or mortar to increase building/wall stability at chosen locations
(corners, junctions, opening ends etc.)
They may be used for electrical and communication conduits.
The grooves may however increase the amount of render required for internal plastering. The
holes in combination with the grooves may reduce overall strength of block and hence the
strength of the wall built using these blocks. The locking mechanism is not well secured as the
knobs and depressions are too small lesser than 5mm. the strength of such interlocks depend on
surface render, or on grout filled into vertical holes with additional reinforcements if need arises.
2.4.5 Solbric system from South Africa
The Solbric system uses solid interlocking blocks, formed by pressing on their ends (the
compacting stroke moves to the longer side), with guided or controlled width and height. In block
laying, SOLBRICs are arranged at the normal bed surface. The size of a SOLBRIC is
250x200x100mm. SOLBRIC provides small horizontal cavities between the courses in which
conduits and pipes can be installed or reinforcements placed to strengthen the wall at certain
locations (cill and lintel levels). The SOLBRIC wall has a flat internal surface and externally a
pointed joint surface from the chamfered edges of the blocks/bricks on one side. The flat internal
surface of SOLBRIC reduces the thickness of required plaster mortar and the external pointed
joint makes the external appearance attractive. However this difference means that bricks/blocks
may not be reversed (front to back).
21


Figure 2. 4: SOLBRIC interlock brick [12]

Although the SOLBRIC interlocking block system seems to be easy to use, the shape of the
block and the parts made from the machine make it possible to build only the external walls
because there is no means of connecting partitions, for example by making a tee or cross joints.
The smaller thicknesses smaller than 15mm of the vertical and horizontal tongues that provide the
interlocking are questionable due to the material used (soil stabilized with cement that is brittle in
nature) [12].
22

2.4.6 Hydraform system from South Africa
Hydraform is the simplest type of interlocking block in shape, when interlocked makes a tongue
and grooved joint at the sides and top and bottom. Being freeto slide alone the course
horizontally. It can be pushed along to achieve tighter perpends (vertical joints).

Figure 2. 5: Hydraform machine

Hydraform block is molded by pressing along its length from the ends, as for the SOLBRIC. It is
also a solid block, but slightly shorter, wider and thicker in size (240x220x115mm) than the
SOLBRIC. The stability of the wall built from the Hydra form blocks are not provided by the
locking mechanism but by the width and weight (massiveness) of the block. In production they
require considerable power to mould (compress) due to their large volume, 30% more soil is used
compared to other reported types. Moreover the compression must be sufficient to allow a fresh
block to withstand the squeezing forces occurring when it is manually moved from machine to the
curing area. A powerful (moulding pressure 4 Mpa to 10 Mpa) and expensive motorized machine
[13] is required to compact such volume of soil. This can be compared to the cheaper manual
presses (with pressures under 2Mpa) used to produce Bamba, Tanzanian and Thai types [14]
The hydraform blocks require some shaving or chopping, if two blocks have to be laid
perpendicular to each other. A half bat to cover the tongue/male is also required (Hydraform
manual 2004).
23

2.4.7 Bamba system from South Africa
The Bamba interlocking block is perforated, with protrusions and depressions. The top and
bottom faces of Bamba have negative symmetry: configurations opposite to each other that allow
them systematically to fit/lock. Bamba block interlock well than all other types due to its shape,
provided that high accuracy is maintained. This accuracy depends on: proper soil selection, proper
determination of material mix (cement to soil and water to cement ratios), observation of good
practice in production and curing. Though the shape can yield a rigid structure, it is very difficult
to correct if blocks have defects. With these contradictory characteristics, the system is not fit for
use in developing countries because it requires accurate machinery and high skills in soil selection
to make sure that the production will be one consistency. If everything is perfect, you can lay the
blocks of a whole house in a day, like a puzzle game. Otherwise, with low accuracy in size and
shape due its complicated configuration, it consumes a lot of time shaving and shimming to
compensate for block irregularities.

Figure 2. 6: The use of Bamba interlocking brick units in stretcher bond.
The author developed threequarter bats for Bamba interlocking block [14] to perform tee and
cross joints. The available Bamba interlocking units can assemble wall, but it is restricted to half
brick wall and just stretcher bond. The occurrences of tee or cross joints alternate the use of three
quarter bats from right to left, this does not depend on the distance from each joint, but the
24

rotation of three quarter bats to meet at the centre of the joint that changes the orientation of the
following block/brick.
2.4.8Auram system from India
This type of interlocking block/brick has some similarities with Bamba and Thai types, but of a
simpler shape with size 295x145x95 mm. figure shows its family of bricks/blocks. It relates more
closely to the Thai system but with no grooves and reduces perforations.

Figure 2. 7: Auram Interlocking Block [14]
Auram the number of three quarter bats required to just one due to shape similarity, compared to
the two required with Bamba interlocking brick. In this type of interlock a three-quarter bat is
used as corner block; this has flat ends, to avoid a semi-circle notch appearing at the external
surface of the wall. The Auram block is more solid and heavier between 9Kg and 10 Kg than the
Thai and Bamba system types at 7Kg to 8 Kg. But the locking mechanism depends entirely upon
25

the bosses and depressions; this will require experiments to examine the optimum height of male
and depth female features less than 10mm to give enough wall punch trough strength.
2.4.9 Tanzanian interlock brick (TIB) system
According to [15] the TIB system was designed by the author after observing the weaknesses in
the Bamba system. The new system (TIB). It was developed for appropriate technology
applications; thus taking into considerations availability and affordability to the users. The
machine, which is locally made and manually operated, is a modification of CINVA-Ram press
machine [16, 17, 15]. The author made important modifications to improve block/brick to suit
Tanzanian requirements. The size of the brick is 300x150x100mm, the same as that of Thai and
Bamba types respectively. The locking knobs and depression are two as for the Auram type, but
they may have various shapes with holes running through the centre of the knobs. The blocks are
chamfered to the front and back edges, providing pointed horizontal and vertical wall joints. This
chamfer gives a good key to the plaster, if plastering is needed (the blocks from the machine are
normally smooth enough to provide good finishing without plastering). The chamfer also reduces
corner friction during block production; thus reducing the ejection force required. The TIB as
other designs systems block available on market fails to satisfy some of the demands from the
building industry, such as the construction of:
Various block bonding joints
Piers (wider than half block length) attached into walls, which conventional (mortared) block
work can easily perform.
Thicker walls (thickness more than half of brick length) and
Different wall configurations (circular, polygonal)
Correcting these deficiencies interlocking building block is a further work of this research.
2.5 STRENGTH ANALYSIS OF BLOCKS
Blocks often have to withstand great compressive stresses. The durability of the masonry depends
upon the strength of the blocks. Common building blocks should have a minimum strength of
35kg/cm
2
. Also the compressive strength of any individual block should not fall below the
average compressive strength specified for the corresponding class of block by more than 20%
26

2.5.1 Testing for compressive strength
The specimen block is immersed in water for 24 hours. The frog of the block is filled flush with
1:3 mortars and the block is stored under damp jute bags for 24 hours followed by immersion in
clean water for three days. The specimen is then placed between the plates of compression testing
machine. Load is applied axially at uniform rate of 14N/mm
2
(140kg/cm
2
) and the maximum load
at which the specimen fails is noted for determination of compressive strength of block given by:
Compressive strength= Maximum load at failure/ Loaded Area of blocks
2.5.2 Compressive strength and other mechanical properties
The compressive strength is the only mechanical property used in block specification. It the
failure stress measured normal to the bed face. Blocks are tested wet, normally with frog filled
with hardened mortar. A considerable variation is found between individual blocks and the list
specimen to be tested to obtain the mean strength. Generally, compressive strength decreases with
increasing porosity, but strength is also influenced by block composition and drying process. The
compressive strength is limited by brittle fracture and is sensitive to individual flow in the sample
under test.
Among strength of blocks, the compressive strength has received a large amount of attention
because the block is primarily meant to withstand compressive stresses. Cubes, cylinders are the
most compression test specimens use to determine compressive strength. The cubes are usually of
100 or 150mm side, cylinders are 150mm wide and 300 mm height,

Figure 2. 8: Compressive Strength Testing Machine
27

We performed this test to measure the strength gained by the block as a function of the time it is
cured. This information can be used for construction purposes to determine how soon after block
production that the blocks can be placed in the wall. This test also gave us an idea of how the
compressive strength and mode of failure of a single block compares to a block system
2.5.3 Factors affecting compressive strength
Arnold W. Hendry in structural masonry (1998) has stated the important factors in determining
the compressive strength of masonry as follow:
1. Unit characteristics: strength; type and geometry like solid, perforated, hollow, relative height;
absorption.
2. Mortar characteristics; strength developed by mix, water/ binding materials ratio, water
retentivity, relative deformation and relative thickness.
3. Masonry: Bond; direction of stressing; local stress and interlocking system.
Some of these factors, such as the unit characteristics, are determined in the manufacturing/
production process, while others, such as mortar properties, are susceptible to variations in
constituent materials, proportioning, mixing and accuracy of construction.
2.6 HYDRAFORM MACHINE DESCRIPTION
2.6.1 Introduction
Hydraform group was established in South Africa in 1988. It has its head quarter in Johannesburg,
South Africa. A Hydraform range of products is marketed in over 50 countries and has a network
of distributors/ offices and representations in Africa and Asia.
Hydraform group has always placed a strong emphasis on providing clients with cutting edge
technologies. By conducting ongoing research and development both in house and in
collabollation with local experts, it continually strives to improve existing products and to create
innovative and appropriate new offerings. [13]
2.6.2 Types of hydraform machine
1. M7E block making machine
28

Hydraform Model M7E Machine is suitable for users having on site block production requirement
with 3 phase power supply or compatible generator back up. A separate pan mixer is required to
feed the machine with mixed material. It is a stationary plant inclusive of hydraulic power pack
including cylinders, compression chamber, precompacting top gate assembly.
2. M7D mobile block making machine
Hydraform Model M7D Machine is suitable for users having on site block production
requirement with pre-fitted diesel engine. A separate pan mixer is required to feed the machine
with mixed material. It is a mobile plant inclusive of hydraulic power pack including cylinders,
compression chamber, pre-compacting top gate assembly all fitted tyre mounted, road worthy tow
hitch trolley.
3. M7MI block making machine with integrated pan mixer
Hydraform M7MI is popular choice with clients looking for complete mobile block making
solution. The Machine is pre-fitted with diesel engine or electric motor and includes hydraulic
power pack including cylinders, compression chamber, pre-compacting top gate assembly ,
loading assembly, all mounted on a robust trailer with tow hitch and road tyres for mobility. This
machine is a block maker with integrated pan mixer with capacity to complement the block
making unit.
4. M7S2E block making machine
Hydraform M7S2E block making machine is a good option for setting up block yard or for onsite
block production at large projects. It is fitted with twin compression chambers to give parallel
production. This machine consists of three separate units: a power pack plus 2 operating work
stations with compaction chambers. The hydraulic power pack is inclusive of an +- 11 kW2 pole
foot and flange 3 phase 440 volt electric motor (+-11kW) Diesel Engine fitted on a static frame,
running 2x compression chambers individually mounted on separate frames, both including
cylinders, pre-compacting top gate assembly, loading assembly. The chambers are connected to
the power pack through extended hydraulic hoses to give workers free movement area.
5. M7TWIN block making machine
29

Hydraform M7 twin machine is suitable for higher block production requirement with option of
machine mobility on site. The Machine is prefitted with diesel engine or electric motor and
includes hydraulic power pack including cylinders, 2 sets of compression chamber including pre-
compacting to gate assembly, loading assembly, all mounted on a robust trailer with tow hitch and
road tyres for mobility.
2.7 ADVANTAGES AND SOME LIMITATIONS OF IBBs
2.7.1 Advantages of IBBs with quarry dust and pozzolanic materials
A local material: The production of block is made from available locally materials, made on site
its self in the nearby area. Thus it will save transportation, fuel, and time and money expenditures.
Limiting deforestation: The fire wood is not needed to produce IBBs. It will save the forests,
which are being depleted quickly in the world, due to short vie developments and mismanagement
of resources
An adapted material: Being produced locally it is easily adapted to the various needs technical,
social, cultural habits/routine.
A transferable technology: It is a simple technology requiring semi- skills, easy to get. Simple
villagers will be able to learn how to do it in short time.
Job creation opportunity: The interlocking building blocks allow unskilled and unemployed
people to get skilled, get a job and rise in social values.
Market opportunity: According to the local context (material, labors, equipment, etc.) the final
price will vary, but in the most cases it will be cheaper with affordable price than fired bricks and
blocks made from cement.
Reducing imports: Produced locally by semi-skilled people, none needed import from far away
expensive materials or transport over long distance heavy and costly building materials.
Cost efficiency: Produced locally with a natural resources and semi-skilled labour, almost
without transport, it will be definitely cost effective.
2.7.2 Limitations of IBBs with quarry dust and pozzolanic materials
Lack of quarry dust and adequate machine to produce it
Unawareness of the need to manage resources
Lack of pozzolanic materials and knowledge of exploitation
30

Pozzolanic materials are available only in small area
Low technical performance compared to concretes blocks
Untrained teams producing a bad quality products
Under stabilization resulting in low quality products
Misunderstanding of pozzolanic materials and quarry dust.
Bonding of quarry dust and pozzolanic materials which is not totally effective.
Low social acceptance due to counter examples (by unskilled, semi-skilled people or improper
quality of materials used and equipment)
2.8 GENERAL ADVANTAGES AND DISADVANTAGES OF IBB SYSTEM
2.8.1 Advantages
System is more rationalized; it has simplicity of handling and laying
Wall erection is faster
Alignment can be completed faster
Quality variation due to mortar joints is eliminated
Erection during cold weather is possible
Dependence of skilled labor is reduced
Load of superstructure can be immediately applied
Ductility can be improved
Unlike mortared joint construction , use small unit does not consume more material but does take
more time
Unit can be manufactured on site using quarry dust and pozzolan materials
Demolition of interlocking block masonry is basically conducted by simply unplugging the dry
stack masonry units allowing the re-use of the units
Least energy intensive and environmentally benign technology
2.8.2 Disadvantages
Hollow system may be unstable to resist certain types of out of plan loading during the
construction; this can be overcome by external bracing or grouting the hollow section at intervals.
Bond patterns are limited thus architecturally more restrictive; Traditional aesthetic appeal may be
compensated by toweled or spray surface treatments
31

Difficult to form curve walls with most interlocking systems(a few systems include solution to
this problem)
Initial seating deformation may decrease strength and stiffness of hollow system
Manufacturing and handling costs are marginally increased due to the stabilization of blocks
Use of hollow systems without partial grouting and surface bonding is restricted
More accessory units may be required and Dimensional tolerance of the units











32


CHAPITER 3
RESEARCH METHODOLOGY
3.1 INTRODUCTION
This chapter will discuss about all laboratory tests carried out in order to analyze composition of
raw materials that were used to produce blocks; quarry dust, pozzolans, lime and clay. Quarry
dust from different quarries in Rwanda especially in Musanze district and STRABAG stone
crusher located at RWAFANDI; based on the rock that present the good property; mixing with
pozzolana also from Musanze district. Afterward making the best mixing proportion between
them to come out with the appropriate material which will be advised to be used in production of
building blocks. It may be stabilized by lime or clay to access the best strength of block. The
laboratory testing methods of blocks is in accordance with ASTM standards. The property of
block which has to be further discussed is compressive strength.
3.2 TESTING OF POZZOLANS FROM MUSANZE DISTRICT
Pozzolana is typically silicates and/ or aluminates that bind with lime to produce binding calcium-
silicate-hydrates and or calcium silicate aluminates, effectively creating a hydraulic lime. The
term pozzolana refers to a natural material of volcanic origin from which the more general term
pozzolana is derived.
3.2.1 Sieve analysis
a. Purpose & Significance
Grain size distribution test is performed to determine the percentage of different grain sizes
contained within samples. The mechanical or sieve analysis is performed to determine the
distribution of the coarser, larger-sized particles of the finer particles.
The distribution of different grain sizes affects the engineering properties of quarry dust as well as
of pozzolan. Grain size analysis provides the grain size distribution, which is required in
classifying samples.
33


b.Fineness modulus
Determine the specific surface of pozzolana- given in cm
2
/g
Determine the fineness by sieving.
3.2.2 Sieve Equipment
Stack of sieves including pan and cover
Balance (with accuracy to 0.01g)
Mechanical sieve shaker
Oven

Figure 3. 1: Sieve analysis equipment (ASTM. 422 Standard test Method)
3.2.3 Sieve analysis procedure
1. Write down the weight of each sieve as well as the bottom pan to be used in the analysis.
2. Record the weight of the given dry sample.
3. Make sure that all the sieve numbers. Place the pan below sieve. Carefully pour the sample into
the top sieve and place the cap over it.
4. Place the sieve stack in the mechanical shaker and shake for 10 minutes.
5. Remove the stack from the shaker and carefully weigh and record the weight of each sieve with
its retained sample. In addition, remember to weigh and record the weight of the bottom pan with
34

its retained fine of the sample. According to ASTM C33-03,the sieve sizes used for fine
aggregates are 4.75mm,2.36mm,1.18mm,600m,425 m, 300m, 212 m,150 m,75 m, pan
Table 3. 1: Sieve analysis results of Pozzolans from Musanze District

Serial n
o
Sieve
size(mm)
Sieve
weight(g)
Sieve
with
sample
weight
(g)
Weight of
sample
retained(g)
Weight of
pozzolana
retained
in (%)
Cumul
ative
weight
retaine
d in
(%)
Fine
particles
passing
in (%)
1 4.75 497.7 542.2 44.5 1.71 1.71 98.29
2 2.36 458.3 483.1 24.8 0.95 2.66 97.34
3 1.18 428.7 828.95 400.25 15.39 18.05 81.95
4 0.600 407.4 786 378.6 14.56 32.61 67.39
5 0.425 386.8 747.1 360.3 13.87 46.48 53.13
6 0.300 330.2 657.8 327.6 12.6 59.08 40.92
7 0.150 313.1 623.7 310.6 11.95 71.03 28.97
8 0.075 311.8 673.45 361.65 13.91 84.94 15.06
9 Pan 392.7 784.4 391.7 15.06
10 2600 316.56

Calculation of fineness modulus
Fineness modulus: Sum of cumulative % retained samples over 100
Fineness modulus: 316.56 / 100 = 3.1656 3
The fineness modulus is 3 thus the average size of fine pozzolan is third size.
35


Figure 3. 2: Sieve analysis curve for pozzolans from Musanze District.
3.2.4 Particle properties
Prolonged grinding results in an increased pozzolanic activity by creating a larger specific surface
area available for reaction. The overall chemical composition of a pozzolan is considered as one
of the parameters governing long term performance (e.g. compressive strength) of the blended
cement binder.
ASTM C618 describes that a pozzolana should contain SiO
2
+ Al
2
O
3
+ Fe
2
O
3
70 weight %.
Many pozzolans consists of a heterogeneous mixture of phases of different pozzolanic activity.
Volcanic ash deposits containing large amounts of volcanic glass or zeolites are more reactive
than quartz sands or detrital clay mineral. The thermodynamic driving force behind the pozzolanic
reaction serves as a rough indicator of the potential reactivity of a (alumino)-silicate material.
Similarly, materials showing structural disorder such as glasses show higher pozzolanic activities
than crystalline ordered compounds.
3.2.5 Mechanical tests of pozzolans
Mechanical evaluation of the pozzolan activity is based upon a comparison of the compressive
strength of mortar bars containing Pozzolans as partial replacement for Portland cement to
reference mortar bars containing Portland cement as binder. The mortar bars are prepared, cast,
cured and tested following a detailed set of prescriptions. Compressive strength testing is carried
98.29
97.34
81.95
67.39
53.13
40.92
28.97
15.06
0
10
20
30
40
50
60
70
80
90
100
0.01 0.1 1 10
%


P
a
s
s
i
n
g


Sieve size in mm
% of fine particles passing
36

out at fixed moments, typically 3, 7, and 14 days after mortar preparation, a material is considered
to be pozzolanically active when it contributes to the compressive strength taking into account the
effect of dilution.
3.2.6 Chemical test of pozzolans
By referring to American Society for testing and materials (ASTM) standard
The ASTM Standard (ASTM C311-77) varies slightly in content from Indian standard. Below is
given a brief summary of the testing methods of ASTM standard.
Pozzolans materials containing reactive silica and/ or alumina which on their own have little or no
binding property but, when mixed with lime in the presence of water, will set and harden like a
cement. Pozzolans, by their diverse and varied nature, tend to have widely varying characteristics.
The chemical composition of Pozzolans varies considerably, depending on the source and the
preparation technique. Generally, a pozzolan will contain silica, alumina, iron oxide and a variety
of oxides and alkalis, each in varying degrees. This presents problems for small-scale
manufactures wishing to use Pozzolans in a lime or OPC- pozzolan mix.
3.2.7 Reaction conditions
The rate of the pozzolanic reaction can also be controlled by external factors such as the mix
proportions, the amount of water or space available for the formation and growth of hydration
products and the temperature of reaction. Therefore, typical blended cement mix design properties
such as the replacement ratio of pozzolan for Portland cement, the water to binder ratio and curing
conditions strongly affect the reactivity of the added pozzolan
The chemical analysis will determine the following characteristics for Pozzolans:
1. Moisture content: it is determined by drying a sample in an oven and weighting to determine the
percentage weight loss.
2. Loss of ignition: This is the loss of weight due to release of volatiles and the weight loss
measured. This applies to Pozzolans which have to be calcined for use. Given as weight
percentage loss.
3. Chemical composition of pozzolans
37

Silicon dioxide (SiO
2
)
Aluminum oxide (Al
2
O
3
)
Iron Oxide (Fe
2
O
3
)
Calcium oxide (CaO)
Magnesium oxide (MgO)
Sulfur trioxide (SO
3
)
Available alkalis
3.2.8 Chemical laboratory equipment


Figure 3. 3: Chemical testing with a tutorial assistant

Figure 3. 4: Used CST chemical laboratory equipment

38

3.2.9 Chemical test procedure for pozzolan sample from G.L.C (Musanze District)

For determining the quantity of SiO
2
contains into sample
1. A sample of 500 mg of pozzolana was taken into a beaker.
2. Adding 1ml of HCl (Chloride acid) together with agitating by an agitator into the beaker.
3. Evaporation of chloride.
4. Then adding NH
4
Cl and a small amount of HCl agitating with a glass rod.
5. Passing the mixture through a funnel with a filter paper cleaned by distilled water.
6. Clean the filter paper with Hcl .
7. Heat the filter paper in an oven set at 95
0
C during 15 minutes.
8. Measuring on a balance the weight of the filter paper ash already heated.
9. The obtained weight correspond to SiO
2
contains into the sample. Here 218.05 mg.
For determining the quantity of CaO contains into the sample
10. Then pour 50ml of the solution into a beaker by adding H
2
O up to 200 ml.
11. Adding N (CH-CH
2
OH)
3
Tri-ethanolamine up to 500 ml.
12. Titrate the solution with [CH
2
N (CH
2
COOH) CH
2
COONa]
2
ethylene diamine tetra-acetic acid
poured from burette.
13. Opening the tap of burette to pour this acid into solution together by agitating.
14. When the solution change the color, immediately record the volume of acid used from burette.
15. Taking volume readings from the burette, then multiply with a value corresponding to CaO on the
table below. Here Volume of 65.84 ml * 0.9417 mg /ml = 62m g.
For determining the quantity of Fe
2
O
3

16. Adding 3 drops of sulfo-calcilate of sodium into 50 mg of titrated solution.
17. Heat and filtrate the solution with an editor.
18. Measure the weight of the filtrated solution then multiply with the value on the table below. Here
= 51.316 mg * 1.3407 = 68.8mg
For determining quantity of Al
2
O
3

19. Adding 3 to 6 drops of acid into titrated solution of Fe
2
O
3

39

20. Heating this solution up to the boiling point, then titrate with CuSO
4

21. Multiply the volume obtained with a value corresponding to Al
2
O
3
from the table. Here 86.51mg
*0.8554= 74mg
Table 3. 2: Values multiplied with titrated compounds

Titrated Chemical compounds Values
TCaO 0.9417 mg/ml
T MgO 0.6770mg/ml
T Fe
2
O
3
1.3407
T Al
2
O
3
0.8554
TCuSO
4
1.0309

Table 3. 3: Chemical test results of Pozzolans sample (0.5 grams).

Composition of Pozzolan sample Measurement in %
SiO
2
( Silicon dioxide) 43.60 %
Al
2
O
3
( Aluminum oxide) 14.80%
Fe
2
O
3
( Iron oxide) 13.76 %
CaO (Calcium oxide) 12.40%
MgO (Magnesium oxide) 7.60%
SO
3
(Sulfur trioxide) 0.38%
Other( K
2
O ; ) 7.46%

40


Figure 3. 5: Graphical representation of chemical test results
3.2.10 Water content determination for pozzolana sample
This test is conducted to determine the water (moisture) content of pozzolana. The water content
is the ratio, expressed as a percentage, of the mass of pore or free water in a given mass of
soil to the mass of the dry sample.
Standard reference:
ASTM D 2216 standard Test method for Laboratory Determination of water (moisture) content
of soil, rock, and soil-Aggregate mixtures.
Testing procedures
Weight the mass of an empty can+ lid: Mc
Weight the can +lid+ moist sample: Mcms
Put the can with a sample in an oven and adjust the temperature between 105
0
C and 110
0
C and
leave it for 24 hours.
Weight the mass of the sample from an oven after 24 hours
Determine the amount of water removed
0
43.60%
14.80%
13.76%
12.40%
7.60%
0.38%
7.46%
Chemical analysis results of pozzolana sample from Musanze district
SiO2 ( Silicon dioxide)
Al2O3( Aluminum oxide)
Fe2O3( Iron oxide)
CaO (Calcium oxide)
MgO (Magnesium oxide)
SO3 (Sulfur trioxide)
Other( K2O ; )
41

Equipment:
Drying oven, Balance, Moisture can.

Figure 3. 6: Equipment for determination of water (moisture) content
Results in moisture (water) content of Pozzolans samples
Table 3. 4: Percentage in moisture content

Specimen
number
Mass of
empty
can + lid
(grams)
Mc
Mass of
can+lid+moistpozzolana
(grams)Mcms
Mass of
can + lid
and dried
pozzolana
(grams)
Mcds
Mass of
pozzolana
solids
(grams)
Ms
Mass of
pore
water
(
grams)
Mw
Water
content,
(w %)
1 72.23 183.21 182.57 110.34 0.64 0.58%
2 72.18 296.70 295.81 223.63 0.89 0.39%
3 72.30 312.42 311.44 239.14 0.98 0.41%
42

4 72.25 387.46 386.43 314.18 1.03 0.33%
5 72.32 428.32 426.70 354.38 1.62 0.46%
Details of calculations for sample 1:
Mc = 72.23 g, Mcms = 183.21g; Mcds = 182.57 g
Ms = 182.57 72.23 = 110.34 g
Mw = 183.21g 182.57 g = 0.64 g
W = 100* 0.64 / 110.34 = 0.58 %
Average water content in 100 grams of pozzolana is

= 0.434 grams of
water

Figure 3. 7: Average water content in 100grams of a pozzolan sample
3.2.11 Summary for pozzolan tests
Pozzolans are materials that contains reactive silica and alumina, which when finely ground and
added to lime, impart a hydraulic property to the binder. A pozzolanic material is by definition a
siliceous or siliceous and aluminous material which are capable of binding calcium hydroxide [Ca
(OH)
2
] in the presence of water at room temperature. Therefore the chemical measurement of this
pozzolanic activity represents a way of evaluating pozzolanic materials. It can be done directly by
0.434
99.566
Average water
content in a sample in
%ge
Dried pozzolana in %
43

measuring the amount of calcium hydroxide of pozzolana consumed over time. The material
properties responsible for the pozzolana reactivity are reactive silica and alumina content, the
specific surface area. The chemical composition of pozzolana is variable and reflects the regional
type of volcanism. SiO
2
being the major chemical component, most unaltered pumices and ashes
fall in intermediate (52-66 weight % SiO2 ) to acid ( >66 wt % SiO
2
) composition range for
glassy rock types. Basic (45-52 wt% SiO
2
) and ultra-basic (<45 wt% SiO
2
) . Al
2
O
3
is present in
substantial amounts in most Pozzolans; Fe
2
O
3
and MgO are present in minor proportions only, as
is typical or more acid rock types. Therefore pozzolana from Musanze district is Ultra-basic.
3.2.12 Lime for pozzolans stabilization
a. Production of lime
Lime is the material produced from the heating or burning in a kiln at temperatures in excess of
850
0
C of limestone (calcium carbonate or calcite, CaCO
3
). This drives off the carbon dioxide held
within the lime to produce calcium oxide (CaO), a highly reactive solid known as quicklime or
lump lime. It can be combined with aggregate and water to produce a mortar or plaster, or
plaster. It was commonly used as the binding agent in the historic mortars of traditionally
constructed building.
Binder: The binding agent, used in conjunction with aggregate and water to create a mortar.
Typical binders used in construction including lime, clay, earth, gypsum and cement.
Pozzolans are fine silica and alumina rich materials which when mixed with hydrated lime
produce cementitious materials suitable for stabilization and construction needs. Pozzolanic
materials and quarry dust reaction takes place when significant quantity of reactive CaO,Al
2
O
3
and SiO
2
are mixed in the presence of water. Usually CaO is added as lime or cement meanwhile
Al
2
O
3
and SiO
2
can be present in the material to develop cementation between quarry dust and
pozzolanic materials in order to produce the blocks with adequate strength. Lime produces
cementation products in the presence of clay minerals with water. Working with pozzolanic
materials and quarry dust, lime is added initial up to about 3% to render the mixture more fiable.
Lime is added subsequently for development of strength and bonding required for the blocks to be
made. The use of a stabilizer in the block production process, improves block strength and
44

resistance to water damage, the most stabilizer to be used is lime where a stabilized block will
contain 5 to 15% of stabilizer, by weight.
Pozzolana stabilization occurs when lime is added to a reactive soil to generate long-term
strength gain through a pozzolanic reaction. This reaction produces stable calcium silicate
hydrates and calcium aluminates hydrates as the calcium from the lime reacts with the aluminates
and silicates solubilized from the clay. The full-term pozzolanic reaction can continue for a very
long period of time, even decades --as long as enough lime is present and the pH remain high
(above 10). As a result, lime treatment can produce high and long-lasting strength gains. The key
to pozzolanic reactivity and stabilization is a reactive soil, a good mix design protocol, and
reliable construction practices.
Benefits of material stabilization include:
1. Very substantial increases in resilient modulus values (by a factor of 10 or more in many cases)
2. Very substantial improvements in shear strength (by a factor of 20 or more in some cases)
3. Continued strength gain with time, even after periods of environmental or load damage (auto-
genous healing)
4. Long-term durability over decades of service even under severe environmental conditions.
b. Properties of natural lime
1. Vapor permeability: The absorption and evaporation of moisture from the materials helps to
regulate humidity. Vapor permeability of lime decreases as compressive strength increases.
2. Flexibility: The elastic nature of lime enables it to absorb minor structural movement associated
with the expansion and contraction stresses that a building undergoes due to changes in
temperature and humidity. Flexibility typically decreases as compressive strength increases.
3. Environmentally friendly: Lime contains no volatile organic compounds, petrochemicals, lead
or other contaminants.
4. Aesthetically pleasing: Lime finishes complement the appearance and visual qualities of natural
stone and brick. Lime finishes show up slight variation in texture and color. Due to the light
scattering properties of the calcium carbonate crystals in lime, it has a surface luster which is
pleasing to the eye. In contrast, cement-based finishes tend to appear flat and dull.
45

3.2.13 Clay occurrence
According to Mackenzie (1963) clay refers to naturally occurring material composed
primarily of fine grained minerals, which is generally plastic at appropriate water contents and
will harden with dried or fired. Although clay usually contains phyllosilicates, it may contain
other materials that impart plasticity and harden when dried or fired. The naturally occurring
requirement of clay excludes synthetics. Based on the standard definition of mineral, clays are
primarily inorganic materials excluding peat, some soils etc; that contain large quantity of organic
materials.
The term clay mineral refers to phyllosilicates minerals and to minerals which impart plasticity
to clay and which harden upon drying or firing.
3.2.14 Clay for Stabilization
The stabilization by chemical additives of soil materials with increased content of clay
components finds in broad application in various construction activities. The various types of clay
and also some easily accessible and less valuable clay soil materials can be included in the group
of soils applied to these purposes. Cement, lime, clay and fly ash from thermal power plants are
usually employed as stabilizing chemical additives. The replacement of cement by clay is of
particular interest due to its lower price. The stabilization process depends on various factors such
as, the structure, the mineral and the granulometric composition of the pozzolans, as well as on
the amount and types of additives. For this reason, the changes in the properties of stabilized
pozzolans are determined experimentally for each pozzolan type.
The knowledge of the process of chemical interaction of the clay minerals with lime and fly ash is
of prime importance for the predictions of the stabilized product properties since the process are
essential for the stabilization. The interaction of the clay components with have been investigated
in order to clarify the effects of the process taking place during this interaction on the physical
mechanical properties of the stabilized product. In this way further route to the increase of the rate
of that process has been sought in order to achieve higher intermediate and final strengths of the
stabilized material.
46

3.2.15 Chemical composition of clay
According to the chemical analysis material clay has the following composition in %
Table 3. 5: Chemical composition of clay [18]

Chemical composition Percentage (%) Chemical composition Percentage (%)
SiO
2
60.26 Al
2
O
3
15.05
Fe
2
O
3
5.24 CaO 5.79
MgO 2.77 K
2
O 2.78
Na
2
O 1.75 Li
2
O 6.36
Source: www.siencedirect.com
3.3QUARRY DUST FROM STRABAG STONE CRUSHER
3.3.1 Sieve analysis
Table 3. 6: Sieve analysis results for quarry dust from STRABAG stone crusher
Serial n
o
Sieve
size(mm)
Sieve
weight(g)
Sieve +
sample
weight
after
sieving
(g)
Weight of
sample
retained(g)
Weight of
sample
retained
in (%)
Cumul
ative
weight
retaine
d in
(%)
Fine
particles
passing
in (%)
1 4.75 508.8 596.1 87.3 17.46 17.46 82.54
2 2.36 444.9 513.3 68.4 13.68 31.14 68.86
3 1.18 424.1 481.0 56.9 11.38 42.52 57.48
4 0.600 400.3 479.59 79.29 15.86 58.38 41.62
5 0.425 378.4 419.9 41.5 8.3 66.68 33.32
47

6 0.300 360.4 427.2 66.8 13.36 80.04 19.96
7 0.150 327.5 380.9 53.4 10.68 90.72 9.28
8 0.075 310.2 337.31 27.11 5.42 96.14 3.86
9 Pan 391.6 410.9 19.3 3.86
10 500 483.08
Fineness modulus
Fineness modulus = Sum of cumulative % retained samples/ 100
Fineness modulus = 483.08/ 100 = 4.8308 5
Thus, the fineness modulus is 5; hence the average size of fine aggregates is fifth size.

Table 3. 7: Sieve analysis curve for quarry dust from STRABAG stone crusher



82.54
68.86
57.48
41.62
33.32
19.96
9.28
3.86
0
10
20
30
40
50
60
70
80
90
100
0.01 0.1 1 10
%

p
a
s
s
i
n
g

Sieve size in (mm)
Fine particles passing
in (%)
48

3.3.2 Water content in quarry dust sample from STRABAG stone crusher

Table 3. 8: Water content in percentage for quarry dust from STRABAG

Specimen
number
Mass of
empty
can + lid
(grams)
Mc
Mass of
can+lid+moist
quarry dust
(grams)
Mcms
Mass of
can + lid
and dried
samples
(grams)
Mcds
Mass of
dry
sample
(grams)
Ms
Mass of
pore
water
( grams)
Mw
Water
content,
(w %)
1 77.1 162.0 160.6 83.5 1.4 1.68%
2 75.7 172.5 170.6 94.9 1.9 2%
3 73.7 182.9 180.9 107.2 2 1.87%
4 74.8 200.6 198.3 123.5 2.3 1.86%
5 76.1 273.7 269.5 193.4 4.2 2.17%
Calculations for sample 1:
Mc = 77.1 g, Mcms = 162.0; Mcds = 160.6g
Ms = 160.6 77.1 = 83.5 g
Mw =162.0g 160.6 g = 1.4 g
W = 100* 1.4 / 83.5 = 1.68 %
Average water content in 100 grams of quarry dust from STRABAG is

=
1.916 grams of water
49


Table 3. 9: Average water content in 100grams of STRABAG quarry dust sample
3.4 QUARRY DUST FROM MUSANZE DISTRICT
3.4.1 Sieve analysis
Table 3. 10: Sieves analysis results for quarry dust from MUSANZE district

Serial n
o
Sieve
size(mm)
Sieve
weight(g)
Sieve +
sample
weight
after
sieving
(g)
Weight of
sample
retained(g)
Weight of
sample
retained
in (%)
Cumul
ative
weight
retaine
d in
(%)
Fine
particles
passing
in (%)
1 4.75 508.8 612.5 103.7 20.74 20.74 79.26
2 2.36 444.9 531.2 86.3 17.26 38 62
3 1.18 424.1 499 74.9 14.98 52.98 47.02
4 0.600 400.3 461.7 61.4 12.28 65.26 34.74
5 0.425 378.4 435.9 57.5 11.5 76.76 23.24
6 0.300 360.4 398.7 38.3 7.66 84.42 15.58
1.916
98.084
Average water content in a
sample in %ge
Dried quarry dust in %
50

7 0.150 327.5 355.19 27.69 5.538 89.958 10.042
8 0.075 310.2 327.31 17.11 3.422 93.38 6.62
9 Pan 391.6 424.7 33.1 6.62
10 500 521.498
Fineness modulus
Fineness modulus = Sum of cumulative % retained samples/ 100
Fineness modulus = 521.498/100 = 5.215 5
Thus, the fineness modulus is 5; hence the average size of fine aggregates is fifth size

Figure 3. 8: Fine particles passing in percentage



79.26
62
47.02
34.74
23.24
15.58
10.042
6.62
0
10
20
30
40
50
60
70
80
90
100
0.01 0.1 1 10
%
p
a
s
s
i
n
g

Sieve sizes in mm
Fine particles passing in (%)
Fine particles passing in
(%)
51

3.4.2 Moisture (water) content for quarry dust from MUSANZE district

Table 3. 11: Moisture (water) content results for quarry dust from MUSANZE district

Specimen
number
Mass of
empty
can + lid
(grams)
Mc
Mass of
can+lid+moist
quarry dust
(grams)
Mcms
Mass of
can + lid
and dried
samples
(grams)
Mcds
Mass of
dry
sample
(grams)
Ms
Mass of
pore
water
( grams)
Mw
Water
content,
(w %)
1 77.1 162.0 158.12 81.02 3.88 4.79%
2 75.7 172.5 169.3 93.6 3.2 3.42%
3 73.7 182.9 177.68 103.98 5.22 5.02%
4 74.8 200.6 194.14 119.34 6.46 5.4%
5 76.1 273.7 265.9 189.8 7.8 4.1%
Calculations for sample 1:
Mc = 77.1 g, Mcms = 162.0; Mcds = 158.12g
Ms = 158.12 77.1 = 81.02 g
Mw =162.0g 158.12g = 3.88 g
W = 100* 3.88 / 81.02= 4.79%
Average water content in 100 grams of quarry dust from MUSANZE is
4793420240410

=
4.546 grams of water.
52


Figure 3. 9: Average water content in 100grams of a quarry dust sample
3.5 COMPARISON IN WATER CONTENT FOR THE TWO QUARRY DUST
The percentage of water content in quarry dust sample from MUSANZE district is much higher
than for a sample from STRABAG stone crusher; this may be caused by weather conditions of
Musanze district usually at low temperature.
3.6 PRODUCTION OF INTERLOCKING BUILDING BLOCKS
3.6.1 Introduction
The production process for the basic elements of wall i.e. blocks from soil, quarry dust and
pozzolanic materials involves either stabilization with cement, clay, lime or even firing. The
process starts with identification and testing of materials (at site and laboratory) to be used to
produce block, followed by preparation (winning/excavations, pulverizing and sieving), mixing
and moulding (by hand, machine pressing or ramming between shutters). Finally drying is needed
for block made with quarry dust and pozzolanic materials stabilized with clay or lime. These
various processes are well covered by [18], [19], [20]
In this competitive world, the production process is the most important part of the building
materials industry. It assures standardized quality and adequate quantity of materials to fulfill the
needs of market. In this research project report , we shall look at the production of Interlocking
building Block(IB), using quarry dust and pozzolanic materials to be stabilized either by clay or
lime, bearing in mind, that the use of soil as quarry dust that is readily available, for construction,
4.546
95.454
Average water content
in a sample in %ge
Dried quarry dust in
%
53

across the economic spectrum and across the various stages of social and technological
development, makes available an appropriate and sustainable technology for the creation of the
built environment [21], [18]
3.6.2 Mixing design for lime/clay, pozzolana and quarry dust materials
The mixing design of quarry dust and lime pozzolana is a process of selecting the suitable
ingredients of block and determining their most optimal proportion which would produce an
interlocking block that satisifies a certain compressive strength and desired workability.
The mix design is based on the principles of
Workability
Desired strength and durability of hardened block
Conditions on site, which helps in deciding workability, strength and durability requirements.
The mixing ratios adopted to be used in this project are 1:1:2; 1:2:4 and 1:3:6 of lime/clay;
pozzolans and quarry dust. Another trial of 1:1; 1:2; and 1:3 of pozzolans and quarry dust will
also be used, for all together with addition of water.
Specimen (block) preparation
The overall dimensions of all produced blocks are 300mm*150mm*120mm with 2 cavities of
50% of the block heigt. The block specimen were molded by Hydraform machine at KINAMBA
road (Poids Lourd)
Hollow interlocking block
It is a block whose net cross- sectional area in any plane parallel to the surface containing cores,
cells, or deep frogs is less than 75% of its gross cross-sectional area measured in the same plane
3.6.3 Block production procedures
Sieving quarry dust and pozzolanic materials through a screen mesh of at least 1x2m with size of
opening of 5mm.
When the component of the samples to be used is not well graded, some other components can be
added, then stabilizer the ratio predetermined.
54

The mixing must be very carefully carried out in order to ensure the intimate mixing of quarry
dust, pozzolanic materials and lime or clay. For plastic mixture. This process should be carried
out in two stages with one or two days in between them.
Hold back time is considered to allow the mixture to rest after mixing. A wait for at least 2 hours
should be allowed for lime.
Compression, dry density plays a great role to the degree of compaction, especially for high
proportions of lime. The moisture content is close to the optimum. The exothermic reaction set off
by quicklime consume close to 1% of the moisture content percentage of quick lime added.
Dry curing is done in order to obtain an increase in the compressive strength; this serves better in
warm and humid environment. Curing the sun under the sheet of plastic or tunnel built. It lasts for
several weeks and persists for some months, it is better in warm and humid environment.
Lime stabilized blocks is more advantageous when subjected to very high temperatures on curing.
This is why curing is done on the sun under a plastic covering. Research has shown that a very
good product can be obtained by drying it for 24 hours for adequate and efficiency strength
Summary of the block production
This involves the following steps:
Loading the quarry-dust and pozzolan materials
Mixing quarry dust; pozzolans and lime-clay with water
Loading Hydraform machine
Carrying the blocks
Stacking and curing the blocks
Laying down the blocks
3.6.4 Hydraform machine blocks product
Hydraform blocks are interlocking blocks that are produced using hydraform block machine. Here
hydraform block machine utilized compressed quarry dust; lime/clay and pozzolana while
producing building blocks, quarry dust lime and pozzolana are mixed with water, then
compressed using this machine to manufacture high quality building blocks. Produced blocks are
interlocking means do not require mortar than conventional bricks or blocks.
55


Figure 3. 10: Used hydraform machine for making blocks









56

CHAPITER 4
RESULTS AND DISCUSSION
4.1 PRESENTATION OF RESULTS
4.1.1 Introduction
This chapter presents the results from experiment undertaken. These results were obtained after
testing different blocks molded from quarry dust and pozzolanic materials with addition of
lime/clay for stabilization of pozzolans. The results are related to the variation of percentage of
pozzolan as well as of quarry dust.
All necessary calculations for determining strength of blocks will be done in this chapter means
determining in which proportion of mixing ratio will appear a high strength block. The
compressive strength of block is the load at failure in compression divided by the apparent
bearing area of the block. In case of hollow interlocking blocks the compressive strength is
calculated on the basis of the solid bearing area of the hollow block
4.1.2 Hypothesis
Structural wall must withstand and resist against natural and artificial action like compressive
stress, capillarity, etc. This will depend on resistance of structural materials that were used to
build that wall; materials here are blocks made with quarry dust and pozzolanic materials with an
addition of lime/clay for accurate stabilization. The test of crushing strength of the product was
made to know the ability of the block to support the applied loads in order to make safe design.
4.1.3 Testing procedures and calculations
Each block was tested in a compression machine at the department of civil engineering, IPRC.
Compressive strength was calculated on the basis of the apparent and effective bearing areas of
the perpendicular surfaces.
Steps in strength calculation
Preparation of samples
Measuring the area to be loaded
57

Weighting the block to be tested
Crushing the block between the two plates of crushing machine
Note the crushing force at failure of the block
Calculate crushing strength
4.1.4 Purpose of crushing strength test
This laboratory test is conducted in order to determine mechanical properties such as compressive
strength and volume density of the block made with quarry dust and pozzolanic materials with
addition of lime. This test will help us to decide whether we can recommend these materials for
making blocks to be used in construction industry.
4.1.5 Equipments

Ruler
Crushing machine from IPRC
Balance
Calculator


Figure 4. 1:Crushing of block equipment
4.1.6 Block dimensioning
Identify the direction in which the block is to be laid.
58

It should correspond to the direction in which the blocks were compressed.
Define the dimensions: Length(L), Width(W) and Height (H)
Length (L): the largest dimension of the block.
Width (W): the block dimensions corresponding to the width of the laying face.
Height (H): The dimension of the block measured in the direction of the compression or in more
general terms, the smallest dimension of the block.
Measure to the nearest millimeter each dimension of the block in the middle of each face and
calculate the averages.
Calculate the volume of the block V = L*w*h (in mm
3
)
4.1.7Area and volume calculations

Figure 4. 2: Hollow block dimensioning

59

a. Calculation of block Volume
Volume of specimen = 300x150x120 = 5 400 000 mm
3
= 5.4* 10
-3
m
3

Volume of 2 hollow = 2 (50 x50 x60) = 300 000mm

3

Net volume of block = 5.4*10

-3
300000 = 5 100 000mm
3
=5.1*10
-3
m
3
b. Calculation of cross section area to be loaded
Total cross-section area of the block = 300*150 = 45 000 mm
2

Cross section of 2hollow = 2(50 x50) = 5 000mm
2

Net cross section area = 45000 5000 = 40 000 mm
2
= 0.04 m
2

Formula for calculating compressive strength
Crushing strength (MPa) =



Volume density =



4.1.8 Results for sample mixing of pozzolan and quarry dust from STRABAG (PQs)
a. Sample for 7 days old specimen
Table 4. 1: Strength of block 7 days after molding (PQs)

Sample
blocks
Pozzolana
in volume
%
Quarry
dust in
volume
%
Mass of the
specimen(kg)
Volume
density
(kg/m
3
)
Crushing
load in
KN
Compressive
strength in
MPa
Block 1 50% 50% 9.3 1823.5 11.3 0.2825
Block 2 25% 75% 9.1 1784.3 8.2 0.2050
Block 3 75% 25% 8.9 1745 6.7 0.1675


60

b. Samples for 14 days old specimen
Table 4. 2: Strength of blocks 14 days after molding (PQs)

Sample
blocks
Pozzolana
in volume
%
Quarry
dust in
volume
%
Mass of the
specimen(kg)
Volume
density
(kg/m
3
)
Crushing
load in
KN
Compressive
strength in
MPa
Block 1 50% 50% 9.2 1804 11.7 0.2925
Block 2 25% 75% 9.0 1765 8.6 0.215
Block 3 75% 25% 8.7 1706 7.1 0.1775
4.1.9 Results for sample mixing of pozzolana and quarry dust from MUSANZE (PQm)
a. Sample for 7 days old specimen
Table 4. 3: Strength of blocks 7 days after molding (PQm)

Sample
blocks
Pozzolana
in volume
%
Quarry
dust in
volume
%
Mass of the
specimen(kg)
Volume
density
(kg/m
3
)
Crushing
load in
KN
Compressive
strength in
MPa
Block 1 50% 50% 9.8 1921.6 10.6 0.265
Block 2 25% 75% 9.5 1862.7 7.9 0.1975
Block 3 75% 25% 9.1 1784.3 5.1 0.1275



61

b. Sample for 14 days old specimen
Table 4. 4: Strength of blocks 14 days after molding (PQm)

Sample
blocks
Pozzolana
in volume
%
Quarry
dust in
volume
%
Mass of the
specimen(kg)
Volume
density
(kg/m
3
)
Crushing
load in
KN
Compressive
strength in
MPa
Block 1 50% 50% 9.2 1804 11.0 0.2750
Block 2 25% 75% 9.0 1765 8.1 0.2025
Block 3 75% 25% 8.7 1706 5.5 0.1375
4.1.10 Results for sample mixing of Lime; pozzolana and quarry dust from STRABAG
(LPQs)
a. Sample for 7 days old specimen
Table 4. 5: Strength of block 7 days after molding (LPQs)

Sample
blocks
Lime in
volume
%
Pozzolana
in volume
%
Quarry dust
in volume
%
Mass of
the
specimen
(kg)
Volume
density
(kg/m
3
)
Crushing
load in
KN
Compressive
strength in
MPa
Block 1 25% 25% 50% 9.7 1902 27.2 0.6800
Block 2 14% 28% 58% 9.5 1862.7 24.8 0.6200
Block 3 10% 30% 60% 9.4 1843 21.0 0.5250



62

b. Sample for 14 days old specimen
Table 4. 6: Strength of block 14 days after molding (LPQs)

Sample
blocks
Lime in
volume
%
Pozzolana
in volume
%
Quarry dust
in volume
%
Mass of
the
specimen
(kg)
Volume
density
(kg/m
3
)
Crushing
load in
KN
Compressive
strength in
MPa
Block 1 25% 25% 50% 9.5 1862.7 28.9 0.7225
Block 2 14% 28% 58% 9.4 1843 26.1 0.6525
Block 3 10% 30% 60% 9.3 1823.5 22.4 0.5600
4.1.11 Results for sample mixing of Clay; pozzolana and quarry dust from STRABAG
(CPQs)

a. Sample for 7 days old specimen
Table 4. 7: Strength of block 7 days after molding (CPQs)

Sample
blocks
Clay in
volume
%
Pozzolana
in volume
%
Quarry dust
in volume
%
Mass of
the
specimen
(kg)
Volume
density
(kg/m
3
)
Crushing
load in
KN
Compressive
strength in
MPa
Block 1 25% 25% 50% 9.5 1862.7 32.3 0.8075
Block 2 14% 28% 58% 9.7 1902 29.7 0.7425
Block 3 10% 30% 60% 9.6 1882.3 26.1 0.6525


63

b. Sample for 14 days old specimen
Table 4. 8: Strength of block 14 days after molding (CPQs)

Sample
blocks
Clay in
volume
%
Pozzolana
in volume
%
Quarry dust
in volume
%
Mass of
the
specimen
(kg)
Volume
density
(kg/m
3
)
Crushing
load in
KN
Compressive
strength in
MPa
Block 1 25% 25% 50% 9.4 1843 33.4 0.8350
Block 2 14% 28% 58% 9.5 1862.7 29.8 0.7450
Block 3 10% 30% 60% 9.3 1823.5 27.1 0.6775
4.2 ANALYSIS OF RESULTS
The type of mixing proportion of pozzolans with quarry dust were practiced in the mortar mixes
that 1:1; 1:3, 3:1 (Pozzolans; Quarry dust) and of 1:1:2; 1:2:4; 1:3:6 (lime/clay; pozzolans; quarry
dust). The hydraulic force applied to compact the block samples is decreased if there are more
content of quarry dust in the mixture. Result can be analyzed that the more content of quarry dust
in the mixture; the block will be easier to compress. The compressive strength of the samples was
determined on the 7
th
and 14
th
days. Results obtained indicate that the compressive strength of
interlocking block made from quarry dust and pozzolanic materials increase with the increase of
age of maturity but well dried at 14
th
day. Mix ratio of 1:1 for pozzolana and quarry, and of 1:1:2
for Lime/clay; Pozzolana and Quarry dust from STRABAG stone crusher gives the highest
compressive strength at 14
th
day. More quarry dust into the block mix resulted the lower
compressive strength. This can partly be attributed to the properties of the quarry dust and
pozzolanic materials which might contribute to the negative effects in the strength of the
interlocking block.
The results obtained from compression strength test indicates that blocks made with pozzolans
and quarry dust from STRABAG stone crusher (PQs) at 14
th
days gives a high compressive
strength of (0.2925 N/mm
2
) compared to the one of quarry dust from MUSANZE district( QPm)
at 14
th
days which is (0.2750 N/mm
2
) .
64

The testing results for lime; pozzolans and quarry dust from STRABAG stone crusher(LPQs) at
14
th
days gives the maximum strength of ( 0.7225 N/mm
2
) as shown in (Table 4.6).
The results for a mixing ratio of Clay; Pozzolans and Quarry dust from STRABAG stone crusher(
CPQs) at 14
th
days gives the maximum strength of (0.8350 N/mm
2
) which is the best strength of
the project.

Figure 4. 3: Presentation of obtained compressive strength results
4.2.1 Variability of compressive strength
The result from samples of interlocking building blocks made with quarry dust and pozzolanic
materials stabilized either with lime or clay showed that the variation of ingredients percentage
and the region where the ingredients were quarried affect the compressive strength of the block.






0.2925
0.275
0.7225
0.835
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
PQs PQm LPQs CPQs
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
n
g
t
h

i
n

M
P
a

Block mixing materials
Presentation of blocks strength
Compressive strength at
14th day in( Mpa)
65

4.2.2 Comparison in strength between project blocks with other types of block

Table 4. 9: Block comparison with other types existing in Rwanda

Types of blocks Size of blocks in
mm
Density in
kg/m
3

Compressive
strength in
N/mm
2

Concrete blocks 300x200x150 2250 5-11
Common burnt clay brick 260x125x115 1275 2.2- 5
Unfired clay block 230 x 230 x 115 1700-2200 0.1- 0.39
IBBs with quarry dust
and pozzolanic materials
300x150x120 1804 0.2925
IBBs with Lime,
Pozzolanic and Quarry
dust
300x150x120 1662.7 0.7225
IBBs with Clay,
Pozzolanic and Quarry
dust
300x150x120 1843 0.8350
Source: Ruliba clays ltd; NPD Cotraco
4.2.3 General comparison of blocks

Table 4. 10: General comparison of blocks

IBBS made with quarry dust and pozzolanic
materials
Different types of blocks listed above
Low compressive strength
Can be produced on site
Are not burnt
Medium density
Unskilled people may be used
Less variability of sizes
Less cost
High compressive strength
Most of them are manufactured
May be burnt
Some of blocks have higher density
It requires skilled people
Most variable size
High cost
66

4.2.4 Checking of hypothesis
From the assumed hypothesis; we said that the block should have the sufficient strength in order
to resist external forces like compressive stresses. Therefore the results obtained from
compression strength test indicates that blocks made with quarry dust and pozzolana materials
stabilized with clay (CPQs) at 14
th
days gives the maximum compressive strength of 0.8350
N/mm
2
. Even if it is the best strength of the project but do not satisfy the minimum compressive
strength of 2.5N/mm
2
provided by international standard. Thus we can conclude that, this block
will not be able to resist loads due to its less compressive strength.















67

CHAPITER 5
CONCLUSION AND RECOMMENDATIONS
5.1 CONCLUSION
This project has been completed under our devoted effort even if the expected result was not
reached but for us we get a lot of experience and knowledge as expected; through different hard
work undertaken. The project was purposely to assess the strength of interlocking building blocks
made with quarry dust and pozzolanic materials so as to provide nowadays, improved technology
to induce people to use interlocking building blocks made from quarry dust and pozzolanic
materials in building houses because they do not require cement mortar in bonding the blocks
during construction, thereby further reducing the building cost. Hence, the pleasing appearance is
not totally maximized and also does not reach the minimum strength of 2.5N/mm
2
required by
BS2028 to the block commonly used in building. Based on experiment testing, crushing strength
have been performed to determine compressive strength of blocks made with quarry dust and
pozzolanic materials with addition of lime/clay to stabilize them in order to increase the bonding
efficiency. From the results of the various tests performed, the following conclusions can be
drawn:
All the blocks produced do not satisfy the minimum requirements in terms of compressive
strength, by all available codes.
Interlocking blocks made from quarry dust and pozzolanic materials stabilized with lime/clay are
denser and so stronger to be used like other varieties of blocks of small strength.
Based on experimental investigation conducted on strength of interlocking building blocks made
in quarry dust and pozzolanic materials, it has been proved that those blocks can be used as an
alternative material for single story buildings due to the following main results:
Strength: The compressive strength of interlocking building block made from quarry dust and
pozzolanic materials is one of properties which must be taken into account while assessing
durability of a building material. The interlocking building blocks having 25% of clay content and
cured 2 days in this project have a minimum value of 0.8350 MPa while the recommended value
is 2.6MPa. This shows that the interlocked blocks of quarry dust and pozzolanic materials
stabilized do not have required strength to be used as an alternative materials blocks. The
68

Compressive strength of interlocking blocks increase with the increase of stabilizing materials
and the curing period

Environmentally friendly: interlocked blocks produced for this project are the best ecological
materials. Since the raw material can almost always be found locally there is no carbon emission
produced during transportation. The ingredients used in production of interlocked building blocks
made from quarry dust and pozzolanic materials. Quarry dust was used instead of sand for
limiting the excessive sand extraction which result the erosion and failure of river banks,
lowering of river beds, damage to the bridge.
Low cost : Use of locally available materials such as quarry dust and pozzolan make IBBs to be
cheaper and affordable .In most parts of Rwanda quarry dust is easily accessible to low -income
groups . One IBBs can cost 100 Rwandan francs and then easy to use; no specialized
equipment is required. Quarry dust is available in large quantities in most quarries.
Easy to build: A major advantage of IBBs construction is that buildings can be rapidly
built using unskilled labor. The skill level required is thus lower than that of burnt bricks.
5.2 RECOMMENDATION
After completing experimental investigation on stabilized blocks made by Hydraform machine,
various observations has been made and we finalize by the following recommendations:
The minimum lime/clay, pozzolana and quarry dust mixing ratio recommended in this research
for the production of hollow interlocking block is 25% of lime/clay, 25% of pozzolana and 50%
of quarry dust in volume percentage and properly dried for 14 days using estimated water ratio.
Structural engineer should be encouraged to carry out more research on the methodology of
quarry dust and pozzolana block production and to produce more paper on the topic.
Correct use of simple testing procedures should be employed prior to any change in the type of
quarry dust used. It will allow the most appropriate use of the available materials and identify
unsuitable quarry dust that should not be used.
We recommend UR-CST to offer partial funds on projects budget to enable final year students
carrying out their research without being limited to data collection, performing some tests, site
visit, etc.
We recommend this project to all coming undergraduates in civil engineering to do a further
research of this project in order to achieve the mere objectives
69

Interlocking building block made from quarry dust and pozzolanic materials should not be used
for multi-storey buildings since they are very heavy compared to the burnt bricks, they can result
into a very heavy structure which can easily settle.
More tests such as flexural strength, split tensile strength, heat transfer are recommended for
evaluating other important mechanical properties for those blocks.
Some admixtures such as Gypsum; GBFS (Granulated Blast-Furnace Slag) which is highly
cementitious in nature and ground to cement fineness and hydrates like Portland cement. All those
should be used in order to increase the block strength.














70

REFERENCES

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72

APPENDICES
APPENDIX 1


Pozzolana at Great Lakes Cement ( Musanze District )
Quarry dust at STRABAG Stone crusher
73

APPENDIX 2


Clay Lime
Used water for mixing
74

APPENDIX 3



Mixing of samples
Drying of
moulded
block
samples