KOYA UNIVERSITY

FACAULTY OF ENGINEERING
CIVIL ENGINEERING DEPARTMENT

BUILDING MATERIALS & TESTING

COURSE BOOK
FIRST STAGE

ACADEMIC YEAR
2015-2016
Building Materials & Testing

Course Information
Academic Year
Stage
Course Title
Course code
Weekly Load
Instructor
E-mail
Department
Coordinator

2015 20165
1st Year
Building Materials & Testing
BMT5104
3 hr ( 2hr practical + 1hr theoretical )
Mr . Sarmad Fadhil Abdullah
Sarmad.fadhil@koyauniversity.org
Civil Engineer

Course Objectives
Building materials have an important role to play in this modern age of technology. Although
their most important use is in construction activities, no field of engineering is conceivable without
their use. Also, the building materials industry is an important contributor in our national economy as
its output governs both the rate and the quality of construction work.
The main goals of this course are studying the building materials starting with their properties,
after that studying various types of materials starting with brick and blocks, gypsum and lime, building
stones and building mortar their properties, testing and usage, then study properties, application and
production of insulation materials, timber, metal, alloys, glass, paints and varnish.

Course Outcome
After completing this course the student will be able to demonstrate competency in the
following area:123456789-

Classification of engineering materials, properties of materials.

Bricks and Blocks (properties, manufacture, usages and testing).
Gypsum and lime (properties, manufacture, usages and testing).
Building Stones (uses of stones , their classification, testing)
Building mortar (definition, properties, types, testing).
Insulation Materials (definition, advantages, types)
Timber (properties, defects, usages and testing).
Metals and alloys (ferrous and nonferrous material, the tensile strength of steel).
Glass (properties, classification and usages).
10- Paints and Varnish (Definition, function, characteristics of good varnish).

Course outcome measures and assessment

1- One and half hour exam during semester
2- Three hours final exam.
3- Course and instructor evaluation to provide student feedback on perceived of the course
and effectiveness of the instructor.

References

Building Materials & Testing

1- Engineering Materials Including Construction Materials by R.K Rajput 2nd

edition.
2- Building Materials by S.K.Duggal, 3rd edition.
Grading Policies
First exam
Second exam
Laboratory exam
Final exam
Total

20 %
20 %
20 %
40 %
100 %
Course policies

1- No cell phone is allowed during the lecture and exam.

2- Be on time in class
3- Exam and quizzes are closed book
4- Review questions will be as a home work if you have any question about them
you can discuss with me at class or office hours.
Lectures Topics
No.
1
2
3
4
5
6
7
8
9
10

Topics Covered
Chapter One: Physical & Mechanical properties
Chapter Two: Bricks and Blocks
Chapter Three: Gypsum and Lime
Chapter Four: Building Stones
Chapter Five: Building mortar
Chapter Six: Insulation Materials
Chapter Seven: Timber
Chapter Eight: Metals and Alloys
Chapter Nine: Glass
Chapter Ten: Paints and Varnish

Building Materials & Testing

Lectures No.

No. of Weeks

Semester

Subject

Chapter Two:
Bricks and Blocks

Theoretical

Practical

Theoretical

Practical

Theoretical

Practical

Chapter Three:
Gypsum and Lime

Teach the students the definition, properties

and classification of gypsum.

10

Theoretical

Teach the students the manufacture and types

of Gypsum and their usages

Give an introduction in building materials and

teach the students physical and mechanical
properties.

Chapter One:
introduction

1st

Subject Goal

Give Introduction and classification of bricks

and teach the students the ingredients of good
brick.
Teach the students the manufacture of brick
and its operations.
Teach the students how to write a report and
divide them into two groups
Teach the students different types of bricks and
where can be used and the defects of bricks.
Explain and apply the procedure of dimension
test of brick and water absorption test then
discuss the results in report according to the
specification.
Teach the students the properties and
manufacture of blocks and how can we choose
the type of blocks.
Explain and apply the procedure of
compressive
strength
of
brick
and
efflorescence test then discuss the results in
report according to the specification.

11

Practical

Explain and apply the procedure of fineness

and consistency tests then discuss the results in
report according to the specification.

12

Theoretical

Teach students the definition, classification

and manufacture of lime.

13

Practical

Explain and apply the procedure of setting

time and flexural tests then discuss the results
in report according to the specification.

Building Materials & Testing

No. of Weeks

Lectures No.

14

Subject

Chapter Four:
Building Stones

Subject Goal

Give the students introduction in building

stones, classification of rocks
Teach the students the characteristics of good
stones, and the uses of building stones.

15

Theoretical

16

Practical

17

Theoretical

18

Practical

19

Chapter Five:
Building mortar

20

Practical

21

Theoretical

Explain and applied the absorption test of

building stone and discuss the results in a
report.
Give the students definition of building mortar
and the constituent materials and their
classification.
Explain the bulk density test of mortar and its
significance.
Teach the students the special types of building
mortar and their properties

22

Practical

Explain the flow test of mortar and its

significance.

23

Theoretical

Teach the students the application of building

mortar.

24

Practical

Explain the compressive and flexural strength

test and their significance.

Exam First course

test the students for the previous subjects

10

11

12

Explain and apply the procedure of crushing

tests (compressive and transverse strength) and
discuss the results in report.
Teach the students the deterioration of building
stone.

13

14

15

Building Materials & Testing

No. of Weeks

Lectures No.

Semester

16

25

Chapter Six:
Insulation Materials

Give the students introduction in insulation

materials and their types.

17

26

Theoretical

Teach the students the properties and

application of heat insulation materials.

18

27

Theoretical

Teach the students the properties and

application of water proofing materials.

19

28

Chapter Seven:
Timber

Teach the students the classification of

timber and characteristics of good timber.

29

Theoretical

Teach the students the defects in timber and

the preservation of timber.

Subject

20

2nd

30

Practical

31

Theoretical

21
32

22

Practical

Chapter eight
33
Metals and Alloys
34

Theoretical

35

Practical

Subject Goal

Explain and the method of testing for timber

includes the specific of gravity and
volumetric changes.
Teach the students the wood products and
the application of these productions.
Explain the method of testing for timber
includes the static bending strength and
impact strength.
Give the students Introduction for a ferrous
and non-ferrous material and their types.
Teach the students the properties and uses of
the iron and steel.

23

24

36

Theoretical

Building Materials & Testing

Explain the tensile testing for steel sections.

Teach the students the types of non-ferrous
materials and their applications.

No. of Weeks

Lectures No.

25

37

Chapter nine
Glass

Teach the students the introduction and

classification of glass.

26

38

Theoretical

Teach the students the properties of glass and

how to test the characteristics of glass.

27

39

Theoretical

Give the students the different application of

glass.

28

Chapter Ten
40
Paints and Varnish

29

41

Theoretical

29

42

Theoretical

30

Subject

Exam Second course

Building Materials & Testing

Subject Goal

Give the students introduction and definition

of paints and varnishes. And teach them the
preparation of paints.
Teach the students the characteristics of ideal
(good) paints and their applications then
teach them the defects in paints.
Teach the students the properties and
characteristics of varnish then give them the
applications of varnishes.
Test the students for the previous subjects.

Final Examination (2012-2013)

1. Justify the following:ABCD-

(20 Marks)

Stone has lost importance as building material.

Alkalis make clay unsuitable for brick production.
Split face concrete block used in exterior walls construction.
Ceiling & exterior walls exposed to sever rain must be isolated.

(5 Marks)
(5 Marks)
(5 Marks)
(5 Marks)

2. Explain the following (Choose Two) :-

(20 Marks)
(10 Marks)
(10 Marks)
(10 Marks)

3. Write short notes on the following (Choose Four):-

(20 Marks)

A- Seasoning of timber, their definition, advantages and methods.

B- Pig iron, definition, manufacture, properties and applications.
C- Lead their extraction method, properties and application.

ABCDE-

Factors affecting on acoustic properties of concrete block.

Classification of timber.
Iron and method of its extraction.
Shakes in timber, their types and how affect on timber properties.
Manufacture of cast iron and methods of casting.

4. Discuss the following:-

(5 Marks)
(5 Marks)
(5 Marks)
(5 Marks)
(5 Marks)
(20 Marks)

A- Aluminum, method of extraction and properties as a building material.

(10 Marks)

B- Engineering, Architects and Carpenter must have skill to deal with mechanical
properties of timber.

5- A- Give an engineering solution on the following:

1- Make thermal insulation of the building economic.
2- Controlling sound level in the building.
3- Efflorescence in bricks.

(10 Marks)
(15 Marks)
(5 Marks)
(5 Marks)
(5 Marks)

(5 Marks)
The blast furnace for manufacture of pig iron contains the following ----, ---&----The advantages of carbon content on steel physical properties are ---- & ------.
Knots in timber classified on basis of form to --------- & ----------.
Bloating in bricks defined as ---------- & cause due to -----------.
Advantages of preservation of timbers are --------- & ------------.

B- Complete the following sentences:12345-

Building Materials & Testing

Answer of the exam

Q-1
A- Stone has lost importance as building material.
As building material stone has gradually lost importance because of :1- The presence of cement and steel.
2- The strength of the structural elements cannot be analyzed.
3- The difficulties in its transportation (which consume a lot of time resulting in
slow of construction).

B- Alkalis make clay unsuitable for brick production.

Because:
1- They make the bricks unsymmetrical.
2- They cause efflorescence when bricks come in contact with moisture, water is
absorbed and the alkalis crystallize.

-----------------------------------------------------------------------------------C- Split face concrete block used in exterior walls construction.

Because:1- Splitface block is similar to standard concrete block.
2- Have a natural stone-like texture and appearance of the split face.
3- it is appearance pleasing.

-----------------------------------------------------------------------------------D- Ceiling & exterior walls exposed to sever rain must be isolated.
Because:The amount of rain fall from one place to another usually represents a risk to
buildings without moisture insulators due to the ability of water to penetrate
directly the roof and various elements of the building.

Q-2
A- Seasoning of timber, their definition, advantages and methods.
Seasoning is the process of reducing the moisture content (drying) of timber in order to
prevent the timber from possible fermentation and making it suitable for use.
Advantages of seasoning timber are as follows:
1. Reduce the shrinkage and warpin..
2. Increase strength, durability and workability.
3. Reduce its tendency to split and decay.
4. Make it suitable for painting.
5. Reduce its weight.

Building Materials & Testing

Methods of seasoning:1-Natural of air seasoning:-The log of wood is sawn into planks of convenient sizes and
stacked under a covered shed in cross-wise direction in alternate layers.
2-Artificial Seasoning:- The prevalent methods of artificial seasoning are as follows:
a- Water seasoning: - 1-The logs of wood are kept completely immersed in running
stream of water,
with their larger ends
pointing upstream.
2- The logs are then kept out in air to dry.
3-It is a quick process but the elastic properties and strength of the
wood are reduced.
b- Boiling in water or exposing the wood to the action of steam spray is a very quick
but expensive process of seasoning.
c- Kiln seasoning: - is adopted for rapid seasoning of timber on large scale to any
moisture content.

B- Pig iron, definition, manufacture, properties and applications.

Pig-iron is the crude impure iron, which is extracted from iron ores, and it forms the basic
material for the manufacture of cast-iron, wrought iron and steel.
The pig iron is manufactured by the following operations
(i) Dressing: Crushed into pieces 25mm, impurities of clay loam and other earthy matter
removed by washing, for magnetic impurities magnetic separators are used.
(ii) Calcinations and roasting:
Calcinations:-Water and carbon dioxide are removed from ores by calcinations.
Roasting:- making the Ares hot and very dry after removal of sulphur.
(iii)Smelting:
Smelting is carried out in a special type furnace known as blast furnace.
The blast furnace contains the following:1-The raw material consists of iron ores,
2-The fluxing materials like limestone
3-Fuel like coal.
Properties of Pig Iron:1-hard and brittle with fusion temperature of 1200C
2-Melts easily.
3-It can be hardened but cannot be tempered and magnetized.
4-Its compressive strength is high but is weak in tension and shear.
5-Pig iron does not rust and cannot be casted or welded.
Uses of Pig Iron:Pig iron is most suitable for making columns, base plates, door brackets.

Building Materials & Testing

10

C- Lead their extraction method, properties and application.

Lead is extracted by
1- Reducing the sulphur content by roasting the raw materials in pots or sintering it in
shallow pallets.
2- It is then smelt in a blast furnace along with flux and coke.
3- Lead taken out of the blast furnace and separated alternately on the basis of melting
point.
Properties:1-Pure lead can be scratched even with finger nail.
2-Highly malleable and can be rolled into thin foils.
3- It has a blue grey colour and dull metallic lusture when freshly fractured.
4-When exposed to moist air it loses lusture due to oxidation.
5-Its relative density is 11.34 and melting temperature is 327 C.
Applications:It finds its principal use in paints as base, lead pipes and joints in sanitary fittings and in
batteries.

Q-3
A- Factors affecting on acoustic properties of concrete block.
The acoustic properties of any concrete block structure depend on
1-the form of construction, the intersections and connections between the blocks
2-The properties of the materials used during manufacture of the blocks.

B- Classification of timber.
1- On the basis of position
a-Standing timber
b-Rough timber
c- Converted timber
2- On basis of grading:a-Structural grading:_ is further divided as:
1. Grading based on known effects of defects.
2. Machine grading.
b- Commercial grading:- Commercial grading is further divided in the following
classes:
Grade A
Grade B
Grade C
Grade D
3- On basis of modulus of elasticity:- The species of timber recommended for
constructional purpose are classified as: Group A Group B
Group C
4- On basis of availability:- According to availability, timber can be of three grades,
namely X, Y and Z.
5- On basis of durability:- Timbers are classified based upon such observations as of:
1-High durability
Moderate durability Low durability

Building Materials & Testing

11

6- On basis of seasoning characteristics:- Timbers are classified depending upon their

behavior to cracking and splitting during normal air-seasoning practice under three
categories:1-Highly refractory (class A).
2-Moderately refractory (class B)
3-Nonrefractory (class C)
7- On basis of treatability:- This classification is based upon the resistance offered by the
heartwood of a species to Preservatives under a working pressure of 1.05 N/mm2 as:(a) Easily treatable.
(b) Treatable but complete preservation not easily obtained.
(c) Only partially treatable.
(d) Refractory to treatment.
(e) Very refractory to treatment.

C- Iron and method of its extraction.

Iron is the most important of the metals used in engineering construction. It is available in
abundance, but does not occur freely in nature.
Extracted Iron from ores:The fundamental chemical principles in the extraction of iron from the ores are very
simple as follow:1- Heating the ores (raw materials) in the presence of a reducing agent.
2- Result in the formation of CO or CO2, librated as a gas, and metallic iron.

D- Shakes in timber, their types and how affect on timber properties.

Shakes are longitudinal separations in the wood between the annual rings. These
lengthwise separations reduce the allowable shear strength without much effect on
compressive and tensile values.
Types of shakes are:Heart Shake Cup Shake
Star Shake
Affects of the shakes on timbers are as follow:1- Affect the quality.
2-Reduce the quantity of useful timber.
3-Reduce the strength.
4-Spoil the appearance and favor its decay

E- Manufacture of cast iron

Cast iron is manufactured by:1- The raw materials are led from the top and the furnace is fired.
2- The impurities of pig iron are removed by oxidation.
3- The molten cast iron is led into moulds of required shapes to form what are known as
cast iron castings
4- The slag is removed from the top of cast iron at regular intervals.

Building Materials & Testing

12

Method of Casting:1-Sand Casting

2- Hollow Casting
3-Vertical Sand Casting
4- Centrifugal Casting
5- Die casting

Q-4)
A- Aluminum, method of extraction and properties as a building material.
Aluminum is extracted from bauxite are as follows.
1. Bauxite is purified.
2. It is then dissolved in fused cryolite which is double fluoride of aluminium and
sodium.
3. This solution is then taken to an electric furnace and aluminium is separated out by
electrolysis.
Properties:
1. It is good conductor of heat and electricity
2. It is a silvery white metal and it exhibits luster on a freshly broken surface.
3. It is rarely attacked by nitric acid, organic acid or water.
4. It is highly resistant to corrosion.
5. It is light in weight, malleable and ductile
6. It melts at about 658C.
7. It possesses great toughness and tensile strength
8. Its specific gravity is about 2.70.

B- Engineering, Architects and Carpenter must have skill to deal with

mechanical properties of timber.
The engineer may properly design columns and beams for various parts of timber
structures , he must be thoroughly conversant with the strength and stiffness of the
available classes of timber. He must also know how various defects and conditions
influence these properties.
The architect must not only appreciates the beauty of various species, the relative ease
with which each may be worked, the tendency to shrink, warp, and check; but he must
likewise be prepared to proportion joints and rafters to carry the imposed loads without
excessive deflection.
The carpenter and the craftsman must also have knowledge of the mechanical properties
of timber in order that they may work it to best advantage.

Building Materials & Testing

13

Q-5) A
1-Make thermal insulation of the building economic.
To make thermal insulation of the building economic the following factors must be
carefully applied:1.The costs of insulating materials.
2.The costs of Labors which will install it.
3.The amount of energy saving for the building as a result of using the insulation.
4.Maintenance costs of insulating materials.

2- Controlling sound level in the building

Architectural styles in controlling the sound level:
1. Planning methods of determining the status of sound sources such as streets then
linked them to buildings and environment.
2. Methods of design the forms of the internal space of buildings.
3. Executive methods by choosing soundproof material.

3- Efflorescence in bricks.

The effect of efflorescence can be minimized by:1- Selecting proper clay materials for brick manufacturing.
2- Preventing moisture to come in contact with the masonry by providing waterproof
and using water repellent materials in mortar.

Q-5) B
1- iron ores, fluxing materials like limestone & Fuel like coal.
2- produces steel of different grades & assists in increasing the hardness and strength of
steel.
3- Round knot & Spike knot
4- defect observed as spongy swollen mass over the surface of burned bricks
& cause due to the presence of excess carbonaceous matter and sulphur in brickclay.
5- Create conditions unfavorable to fungi & Coating the surface of timber with polymer
films that can be minimize the water absorption, decay and other undesirable effects

Building Materials & Testing

14

Final Examination (2014-2015)

Q-1)

Write an engineering solution for the following:-

(20 Marks)

a. Selecting proper insulation materials.

b. Make thermal insulation of building economy.
c. Improve the sound insulation of a building.
d. Selecting building material.
e. Controlling percentage of voids.

Q-2) A- Write short notes on the following:- (choose four)

abcde-

(8 Marks)

Using of building mortar.

Architectural styles in controlling the sound level.
Maximum diameter of sand should be limited for making building mortar.
Production of gypsum.
How to choose a concrete block.

B- Solid brick samples of dimensions (24117) cm were tested for water absorption
and efflorescence, the test results are shown in table below:(12 Marks)
Test data
Efflorescence
area (cm2)
Dry weight
(gm)
Saturated
weight (gm)

1
75

2
100

3
140

4
200

5
220

1400 1475

1600

1410

1845 1800

2010

1700

6
50

7
75

8
110

9
175

10
150

1300 1375 1400

1550

1750

1550

2000 1745 1840

1740

1940

1740

Answer the following: 1- Calculate the percentages of absorption for these samples.
2- Calculate the percentage of efflorescence for these samples if bottom and both
faces is affected.
3- Determine the type of bricks and where you can use it according to Iraqi
specification?
Maximum Water absorption (%)
Type of brick

Average of 10 bricks

Class A

20

one brick
22

Class B

24

26

Class C

26

28

Building Materials & Testing

15

Q-4) Describe in details the following:- (choose two)

(20 Marks)

a- Sound insulation of building.

b- Decorative and insulating building mortars.
c- Composition of building mortar.
Q-5) Determine the class of each type of building stone according to Iraqi specification have
been tested in lab for total absorption and specific density, the test results are shown
in the table below.

Test Data
Dry weight (gm)

(20 Marks)

1
1500

2
1550

3
1750

4
1350

5
1200

6
1210

1600

1650

1850

1450

1250

1275

1750

1700

1900

1300

1350

1375

750

800

900

600

710

750

Saturated surface dry

weight after 24 hrs
(gm)
Saturated surface dry
weight after 48 hrs
(gm)
Weight in water (gm)

Classes
Class A (low density)
Class B (medium
density)
Class C (high density)

Building Materials & Testing

Minimum Specific Density

Maximum water absorption

(Kg/m3)

(%)

1750

12

2150

7.5

2250

16

Student feedback regarding the course

Course:
Department:

Date:

Year:
college:

Teacher:
University:

No.

Assessment questions

Were the aims and message of the course

clear?
Were the contents of the course useful?
Was it related to the main aims of the
department?
Do you think the course teacher worked
hard to prepare the course book?
Did the teacher highlight the core topics
and points in an easy-to-understand
manner?
Did the teacher arrive and conclude the
lectures on time?
Did the teacher behave in a professional
manner during the lecture?
Were the slides that were used clear and
comprehensive?
Did the teacher leave any time for
questions and answers? Did he/she answer
them satisfactorily?
Did the teacher handle any criticisms or
complaints?

9
10
11
12

Level (1-5)

More objective notes

Were exam procedures clearly explained?

Did the exam questions reflect the topics
presented and studied in the course?
Were the reading references new and
relevant to the topic?
Total level

Assessment measurement
1- <2 Not Good

Building Materials & Testing

2- <3 Average

3- <4 Good

4-5 Very Good

17