Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

1. INTRODUCTION Ferrocement Ferrocement is a form of reinforced concrete that differs from conventional reinforced or prestressed concrete primarily by the manner in which the reinforcing elements are dispersed and arranged. It consists of closely spaced, multiple layers of mesh or fine rods completely embedded in cement mortar. A composite material is formed that behaves differently from conventional reinforced concrete in strength, deformation, and potential applications, and thus is classified as a separate and distinct material. It can be formed into thin panels or sections, mostly less than 1 in. (25 mm) thick, with only a thin mortar cover over the outermost layers of reinforcement. Unlike conventional concrete, ferrocement reinforcement can be assembled into its final desired shape and the mortar can be plastered directly in place without the use of a form. The term ferrocement implies the combination of a ferrous reinforcement embedded in a cementitious matrix. Yet there are characteristics of ferrocement that can be achieved with reinforcement other than steel meshes or rods. For instance, the ancient and universal method of building huts by using reeds to reinforce dried mud (wattle and daub) could be considered a forerunner of ferrocement. The use of non-metallic mesh is being explored at several universities. Such meshes include woven alkali resistant glass, organic woven fabrics such as polypropylene, and organic natural fabrics made with jute, burlap, or bamboo fibers. Ferrocement trends Widespread use of ferrocement in the construction industry has occurred during the last 25 years, but the usage of this new construction material in the U.S. is still in its infancy. The main worldwide applications of ferrocement construction to date have been for silos, tanks, roofs, and mostly boats. The construction of ferrocement can be divided into four phases: 1. Fabricating the steel rods to form a skeletal framing system; 2. Tying or fastening rods and mesh to the skeletal framing; 3. Plastering; and 4. Curing. Note that relatively low level technical skills are required for Phases 1 and 3, while Phase 2 is very labor-intensive. This is a shortcoming for industrially developed countries but an advantage for countries where unskilled labor is relatively abundant. In developed countries where labor is relatively expensive,

shotcreting , mechanized fabrication of reinforcement cages,1 or laminating techniques similar to those developed for marine structures can reduce the labor cost.2,3 Experience has shown that the quality of mortar and its application to the mesh are the most critical phases. Mortar can be applied by hand or by shotcreting. Since formwork is usually not required, in contrast to conventionally reinforced concrete construction, ferrocement is especially suitable for structures with curved surfaces, such as shells and free-form shapes. In some instances, its use as a permanent form for a reinforced concrete structure can be economically justified.4 Ferrocement has a very high tensile strength-to-weight ratio and superior cracking behavior in comparison to conventional reinforced concrete. This means that thin ferrocement structures can be made relatively light and watertight. Hence, ferrocement is an attractive material for the construction of boats, barges, prefabricated housing units, and other portable structures. However, even though for these applications ferrocement is more efficient on a weight basis, it is frequently more economical to build with conventionally reinforced concrete. This is especially true in developed countries where, due to higher material cost and the labor-intensive nature of ferrocement, its use is limited to specialized applications such as domes, wind tunnels, roof shells, mobile homes, modular housing parts, tanks, and swimming pools. While construction with ferrocement may not be cost-effective in many applications, this material competes favourably with fibreglass laminates or steel used in special structures. Two feasibility studies have shown ferrocement costs to be less than those of steel or fibreglass in the construction of wind tunnels5 or hot water storage tanks.6 It is believed that the development of new mesh reinforcing systems and more efficient production techniques will make ferrocement competitive in a wide range of applications requiring thin structural elements. 2. LITERATURE REVIEWS 2.1 Structural behavior of ferrocement system for roofing Wail N. Al-Rifaie 1 and Muyasser M. Jomaah2 The growing need for cheaper construction is muchdiscussed subject. Prefabricated ferrocement panels present a series of possibilities for the solution of construction problem. By using the unique properties of ferrocement with a relatively low amount of reinforcement, be composite floor and wall panels

Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

can assembled into an effective multi-purpose panel system. The major advantages of this system over current construction methods are mainly due to the reduction in structural dead load and the use of fewer building elements, which are much easier to handle. In the present investigation, two ferrocement channel-like beams to form I-cross section beam are cast and tested due to flexural loading. The structural behaviour was monitored by reading the deflection and by observing the crack patterns. The measured values of deflections and the observations made indicated that ferrocement can be used in construction of buildings. EXPERIMENTAL WORK In order to study the structural behaviour and ultimate strength of ferrocement I cross section beam models by having two ferrocement channel-like cross section beams when subjected to point load. Each of the two channel beams is to be rotated 90 degrees and fixed back to back. Other two ferrocement channel beams were considered to support the slab specimens during their flexural tests. The four ferrocement channel-like cross section beam models were cast and tested, in which each of the four channel beams having a total length equal 2 meter were fabricated using the timber and play wood as formworks. The cross Sectional dimensions and reinforcing details are shown in Figure 1.

All dimensions are in mm Fig. (1): Details of cross section of the tow beams.

TESTING PROGRAM As it was mentioned earlier that the present investigation concerned of studying the structural behavior of ferrocement I-section made of two ferrocement channel-like cross-section beams under flexural load by means of patch load at mid-span as shown in Figure 1.The beam specimens were tested in a 2450 kN capacity hydraulic Avery-type testing machine. Hinged end conditions were considered. All beam models were painted white before testing so that cracks would be easily observed. Beam model was positioned on the support with a clear span of 1.8 m, so that the following criteria are satisfied: i. To restrain all the end movement of the beam model. ii. To restrain the rotations about the longitudinal axis. iii. To permit free rotations of the end beam model normal to their plane, i.e., about the transverse axis. Having placed and accurately aligned the I-section beam in testing machine, 100 mm square steel plate of 5 mm thickness was placed in its position and the load was applied as shown in Figure 1. The dial gauge was fixed at its appropriate location and the initial reading of dial gauge was recorded at the beginning of the test. The dial gauge readings were taken at least 2 min after each load increments to allow for the reading to become stable, and crack initiation was marked. The load application was continued until deformation became excessive. The load was applied in increment of 10 N in a 2450 kN capacity hydraulic Avery-type testing machine and

Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

mid-span deflections were measured. The applying load was continued until failure occurred. RESULTS 1. In Figure 3 the measured deflection values versus applied loads for the I-beam model are plotted. 2. It may be seen that the load-deflection curve for beam model is linear up to ultimate (failure) load. 3. The ferrocement I-beam was cracked at the web at each of bolt position and the cracks pattern are shown in Figure 4. The failure of the ferrocement I- beam occurred first by having fine cracks in the webs at the bolts position, then the length of cracks and their width were increased. It was noticed that there was no sign of cracks at flanges. 4. For slab specimens, in general, all slabs were cracked at the middle along the width (one way action) 5. Slab specimen having 20 mm thick with 4 layers of wire mesh (S2), the failure occurred on the slab specimen with a total load of 30 N. The crack pattern is shown in Figure 5. 6. It was noticed before testing, cracks were exist for slab S1 (20 mm thick, with two layers of wire mesh), So that, the test was neglected. 7. Slab specimen S3, the ultimate load was 20 N. The crack pattern is shown in Figure 6. 8. Slab specimen 30 mm thick with 4 layers of wire mesh (S4), the failure occurred on the beams along the span (beam action). The failure load was 64 N with fine cracks at slab specimen as shown in Figure7 CONCLUSIONS This investigation has shown that, for low cost housing, the proposed ferrocement flooring and roofing system can be satisfactorily used as housing components.

Fig. (2):Tow edges simply supported beams.

Fig. (3):Measured deflection values versus applied loads . 2.2 Torsional capacity of high strength concrete beams jacketed with ferrocement u-wraps G. Charan Behera*, T.D. Gunneswara Rao and C.B.K. Rao Jacketing with composites on the outer periphery is one of an effective way to enhance the torsional capacity of distressed reinforced concrete structures and to change the mode of failure from brittle to ductile. Ferrocement due to its better crack arresting capacity and better strain distribution across the section make it one of the suitable composite materials in the field of strengthening reinforced concrete members. An experimental program consisting of casting and testing of beams with U wraps (more commonly used strengthening technique) was conducted in the laboratory to study the effect of aspect ratio (ratio of depth to breadth), constituent materials of ferrocement (viz., number of mesh layers, yield strength of mesh layers and compressive strength of mortar) and concrete strength on ultimate torsional strength and twist. This experimental results briefly recounts that wrapping on three sides enhance the ultimate torque and twist. This strengthening scheme is more effective for

Fig. (4):Bolt position and the cracks pattern.

Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

higher aspect ratios with high strength jacketing material. An analytical model proposed in this paper for prediction of torque and twist response of jacketed beams is in good agreement with experimental results. Experimental Program (Test beams) Seven beams were cast for validation of the proposed theoretical model .The size of five beams are (125250) mm and other two are of size (125190) mm and (125315) mm. The lengths of the beams were kept 2000mm long with a view to allow two spirals for observation of crack pattern which requires a length of 1500mm for beam size (125250) mm and the end zones of 250mm were kept for fixing lever arms. The ends were reinforced heavily to force the failure to the central zone. 25 mm thick ferrocement shell was prepared on outer perimeter without wrapping on top face. The central concrete core of size (75225) was taken for beams of dimension (125250), (75165) mm for beam size (125190) mm and (75290) mm for beam of size (125315) to fill up with different grades of concrete. Specimen preparation:Three moulds of size (125190)mm, (125250)mm and (125315)mm were prepared for casting of seven beams. The U shape mesh layers were put in mould. Mortar was filled upto 25mm in bottom and then a closed hollow box of core concrete size was put as shown in Figure 2. Mortar was poured from top to fill up outside the closed box section in bottom and side face with continuous vibration through a needle vibrator to allow mortar to insert through mesh layers properly. After the initial setting time hollow box section was taken outside and the ends were provided with reinforcement cage and concrete was filled up in the core. After 24 hours the mould was removed and the specimen was put in curing tank. The casting of ferrocement shell was shown in Figure 3 and Figure 4

Mortar is filled through wire mesh Leaving the core portion

Ferrocement shell in the mould ready for casting of core concrete

Figure 5. Torsion test rig along with twist meter Test setup The specimens along with companion specimens were kept for curing for 28days. After 28 days of curing the beams along with companion specimens were taken out of curing tank and made dry, properly white washed and marked for fixing the twist meters and loading frames. The jacketed beams were tested in the test rig as shown in Figure 5. Rollers in the lateral direction at the reaction end were provided to allow the beam to slide freely along the longitudinal

Placement of wire mesh with solid mould for pouring mortar

Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

direction to avoid any axial restraint. The loading end was supported on a circular roller placed to allow the beams to twist under pure torsion. The twist was measured with the help of the twist meter frame. The loading frame was kept perpendicular to longitudinal axis of beam to avoid bending. Neoprene pads were provided between beam sides and loading frame plates to avoid crushing of ferrocement at longer faces at ends. The load was applied gradually through the load cell. The companion specimens related to the beams were tested on the same day.

3. Increase in core concrete strength increases the cracking torque due to increase in the tensile strength. The ultimate torsional capacity is again not only dependent on this tensile strength, but depends on the stress induced on the longer face. The ultimate capacity of a U wrapped plain concrete beam is governed by strength of core concrete, strength of jacketed material and aspect ratio. 4. The torque and twist of U wrap beam increases by 59.72% and 91.53% respectively compared to an unwrapped concrete beam. 2.3 Study on the Performance of Reinforced concrete Beams Retrofitted Using Ferrocement and GFRP Anugeetha B., Sheela S. Many reinforced concrete structures in our country such as bridges and buildings are in a deteriorated or distressed state. Hence strengthening such structures or reducing the load limit on them is becoming necessary to extend their service life. Nowadays, Ferrocement and composite materials like Glass Fibre Reinforced Polymer (GFRP), Carbon Fibre Reinforced Polymer (CFRP) etc. are widely used for retrofitting reinforced concrete structures. Here, an attempt has been made to determine the effect of number of layers of wire mesh on the performance of the beams retrofitted using ferrocement. The effect of number of layers of GFRP on the performance of retrofitted beams was studied. From the experimental investigation it was found that the ultimate load carrying capacity of beams retrofitted with ferrocement having one, two and three layers of wire mesh increased by 6.25%, 50% and 81.25% and that of GFRP retrofitted beams with 1, 2 and 3 layers increased by 50%, 68.75% and 81.25% respectively. The beams retrofitted with one layer of GFRP in the flexural zone showed a higher strength-to cost ratio. EXPERIMENTAL PROGRAMME The experimental investigation was carried out on beams retrofitted using ferrocement and GFRP by varying the number of layers. It consists of the following stages. Preparation of Beam Specimens: In the present study, an experimental investigation has been carried out in Reinforced Concrete beams of size 120mm x 200mm x 1200mm. M20 concrete mix of proportion 1 : 1.75 : 3.70 was designed and used for the study [12]. Plywood moulds of the size of the

Discussion on Test Results The first crack for plain concrete beams jacketed with ferrocement U wraps appeared on the unwrapped concrete face. The beams failed with single potential crack on the top of concrete face shown in Figure 6 and similar observations are reported by earlier researchers also [11]. However first crack appeared on wrapped longer faces for beams BO4H1,CO4H and on further loading few more small segmental cracks were noticed. The ultimate failure was found to be due to the formation of single crack on unwrapped face with inclination of approximately 45 to the longitudinal axis. De-bonding was noticed at the interface of concrete and ferrocement at failure.

CONCLUSIONS 1. The elastic torque is independent of number of mesh layers in ferrocement. 2. The torsional strength of jacketed beam increases with increase of aspect ratio provided the failure is governed by the shear stress developed on the wrapped face.

Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

beams were fabricated for the preparation of concrete beams. The reinforcement cage was placed in the mould correctly in position by providing the required cover. The reinforcement required for the preparation of the beam was calculated, assuming minimum reinforcement [13]. It consists of 2 numbers of 8mm diameter bars as tension reinforcement and 2 numbers of 8mm diameter bars as stirrup holders. Two legged 6mm diameter bars @ 200mm c/c was used as shear reinforcement. The reinforcement details are shown in Fig.1

fibre of required size and shape was placed over the saturant and is gently pressed to the beam surface using hand pressure. To the surface of GFRP, again a coat of saturant was applied. Then it was left to cure for 3 days. For beams with more than one layer GFRP sheets, a coat of saturant was applied over the previously applied layer of GFRP sheet after curing of first layer and then the next layer of sheet was placed and pressed using hand pressure and the process is repeated for the additional layers of GFRP. Designation of specimens prepared is shown in Table II. Test Procedure: After curing, the beams were tested in 300T UTM. The beams were subjected to third point loading to determine their load carrying capacity. During testing, observations were made for failure load, deflections at one-third span and midspan locations, crack pattern and failure pattern. The deflections at one-third span and midspan locations were determined using dial gauges. The strains at top and bottom of midspan section was determined using Demec Strain Gauge. The schematic diagram of test setup is as shown in Fig.3. Specimens were loaded to failure and the load-deflection plots were plotted for each type of beam. Cost analysis of each method was also done. The typical Load-deflection plot and strain plot for specimen FRB3 are shown in Fig. 4 and Fig. 5 respectively.

Fig. 1 : Cross Section of the Beam showing Reinforcement Details

GFRP In order to apply GFRP the surface of the specimens were cleaned properly using a wire brush. Then a coat of primer, Nitowrap 30 was applied at the desired locations using a brush and a uniform thickness was maintained. Then it was left to 24 hours curing in air. Then one coat of saturant was applied over the primer coat with uniform thickness. Immediately after applying the saturant the glass

Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

Comparison of First Crack Load and Failure Load of Specimens: First crack load and Failure load of all specimens tested are given in Table III. It was observed that all the specimens failed due to flexural failure. The ferrocement retrofitted beams did not show any debonding when loaded to failure. All the retrofitted beams showed a considerable increase in load carrying capacity. The percentage increase in strength was high for FRB2, FRB3, GRB2 and GRB3. FRB3 and GRB3 showed 81.25% increase in ultimate load carrying capacity. This indicates that in the case of ferrocement retrofitted beams, as the number of layer of wire mesh increased, the percentage gain of strength also increased. A graphical representation of the Failure Load and First crack load of all specimens are given in Fig.6 and Fig. 7 respectively. CONCLUSION Based on the test results obtained from the experimental study, the following conclusions may be drawn out, 1. The ultimate load carrying capacity for the beams retrofitted with one, two and three layers of wire mesh increased by 6.25%, 50% and 81.25% respectively. 2. The ultimate load carrying capacity for the beams retrofitted with one, two and three layers of GFRP increased by 50%, 68.75% and 81.25% respectively. 3. The failure of controlled beam and retrofitted beams were characterized by the formation of flexural cracks in the tension zone. 4. The deflections of the retrofitted beams were lesser than that of the control beams. 5. In the case of ferrocement retrofitted beams, beam with three layers of wire mesh showed lesser deflection and higher strength-to-cost ratio. 6. The strength-to-cost ratio was higher for the beam retrofitted with one layer of GFRP. 7. In the case of ferrocement retrofitted beams, the strength-to-cost ratio was found to increase with increase in the number of layers of wire mesh. However, the number of layers of wire mesh in a particular thickness of ferrocement laminate could not be increased beyond a certain limit. 8. The percentage increase in strength per cost of retrofitting was almost similar for beams retrofitted with ferrocement having 3 layers of wire mesh and that retrofitted with 2 layers of GFRP. The cost of retrofitting for FRB3 was found to be 19.6% greater than that of GRB2 and the percentage increase in strength for FRB3 was 18.18% greater than that of GRB2. Thus, retrofitting of beams using GFRP advisable in areas where it is less expensive.

Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

2.4 Effect of Wire Mesh Orientation On Strength Of Beams Retrofitted Using Ferrocement Jackets Prem Pal Bansal*, B.E. Civil, M.E, Civil (Structures) Dr. Maneek Kumar, B.E. Civil, M.E, Civil (Structures),Ph.D. Dr. S.K. Kaushik, B.Tech. Civil, M.E, Civil (Structures),Ph.D. Various retrofitting techniques are used in field and out of all plate bonding technique is considered as the best. In this technique, the plates of different materials viz CFRP, GFRP, ferrocement etc are bonded to the surface of structural member to increase its strength. Ferrocement sheets are most commonly used as retrofitting material these days due to their easy availability, economy, durability, and their property of being cast to any shape without needing significant formwork. In the present work, effect of wire mesh orientation on the strength of stressed beams retrofitted with ferrocement jackets has been studied. The beams are stressed up to 75 percent of safe load and then retrofitted with ferrocement jackets with wire mesh at different orientations. The results show that the percent increase in load carrying capacity for beam retrofitted with ferrocement jackets with wire mesh at 0, 45, 60 degree angle with longitudinal axis of beam, varies from 45.87 to 52.29 percent. Also a considerable increase in energy absorption is observed for all orientations. However, orientation at 45 degree shows higher percentage increase in energy absorption followed by 60 and 0 degree respectively. EXPERIMENTAL PROGRAMME To carry out the investigation, eight prototype beams of size 127mm x 227mm x 4100mm reinforced with two bars of 10 mm diameter in tension and two bars of 8mm diameter in compression were cast using the proportioned mix as shown in Fig.1. Out of these eight beams, two were used as control beams (TypeA) and tested to failure to find out the safe load carrying capacity corresponding to the allowable deflection as per IS:456-2000 i.e. span /250. The other six beams were stressed to 75 percent of the safe load obtained from the testing of the control beams and were then retrofitted with 15 mm thick ferrocement jackets made with 1:2 cement sand mortar and w/c ratio 0.40 as shown in Fig. 2. The jacket was reinforced with single layer of 40mm x 40mm square welded wire mesh. The three wire

mesh orientation viz. 0, 45, 60 degree were used in the ferrocement jackets. The set of beams (two each) were divided into four categories depending upon the orientation of wire mesh in the jacket. Control beams were designated as type-A, whereas, beams retrofitted with welded wire mesh oriented at 0 degree were designated as type B beams. Retrofitted beams having welded wire mesh oriented at 45 degrees and 60 degrees were designated as type C and type-D, respectively. The same are shown in Plate 1

Fig. 1 Longitudinal and Cross-Section of an retrofitted Under Reinforced Beams (All Dimensions are in mm)

Figure 2: Longitudinal and Cross-Section of Retrofitted Beams

(a) 0 degree Orientation

Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

(b) 45 degree Orientation

Plate 1: Test Setup RESULTS AND DISCUSSION First, the two control beams were tested to failure. The load corresponding to an allowable central deflection of 15 mm (span/250) was obtained from load deflection curve as 12.67 kN. The remaining six beams were stressed to 75 percent of this average safe load i.e. 9.50 kN. Subsequently the retrofitting of beams using different orientations of wire mesh in the ferrocement jackets was carried out. These retrofitted beams were then loaded to failure and the data was recorded in the form of load and deflection. Table 5 presents this data for the control beams and beams retrofitted using specified wire mesh orientations. Fig 4 shows the load deflection behaviour at the mid span points of the control as well as beams retrofitted with different wire mesh orientations. It is observed from the curves in Fig 4 that with an increase in load there is a considerable increase in deflection for all the beams. It was also noted that the spacing of cracks was 45mm in case of beams retrofitted with wire mesh at zero degree as compared to beams retrofitted with wire mesh at 450, for which it was 85mm. The spacing increased to 108 mm for 60degree orientation. This shows that the distribution of stress with wire mesh at zero degree is better. It is also observed that corresponding to the serviceability requirement of 15 mm deflection, the load increased from 12.67 kN for the control beam to 14.15 kN, 13.25 kN, 15.41 kN for type B, C and D retrofitted beams, respectively. CONCLUSIONS Based upon the test results of the experimental study undertaken, the following conclusions may be drawn: 1. The beams retrofitted with wire mesh at different orientations do not de-bond when loaded to failure. 2. The failure of the composite is characterized by development of flexural cracks over the tension zone.

(c) 60 degree Orientation Plate 2 Different Wire Mesh Orientations Testing Arrangement All the eight simply supported beams were tested with an effective span of 3.75 m. Two concentrated loads were applied at 1m spacing for testing (see Fig -3). The beams were tested using hydraulically operated jacks connected to a data acquisition system through the load cells. With an increase in load the deflection in the beam was noted using three dial gauges placed at the quarter span points. The same is shown in Plate 2 Process of retrofitting Firstly the surface of beam is cleaned. After cleaning the surface, the cement slurry is applied as bonding agent to the surface of beam. After the application of bonding agent retrofitting of beam is done by applying 15mm thick cement mortar on the three faces as ferrocement jackets having wire mesh at different orientation. The beams are cured for 7days before testing. Then with same procedure as of control beam, testing of beam is done in order to calculate ultimate load and corresponding deflections.

Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

The spacing of cracks is reduced for retrofitted beams indicating better distribution of stress. 3. Wire mesh orientated at 45 degree for retrofitting the stressed beams has the highest load carrying capacity as compared to control beam as well as the other beams retrofitted using different orientations. 4. After retrofitting, all the test specimens showed reduced crack widths, large deflection at the ultimate load, a significant increase in the ductility ratio, and considerable increase in the energy absorption as well, making the components better equipped to resist dynamic loads. 5. Beams retrofitted with wire mesh oriented at zero degree were the most efficient as their cost to strength ratio is lowest. 2.5 Utilization of Ferrocement as Flexural Building Member (Applied as a Hollow Box Joist) R Abasolo, C Bandivas, JV Guinita, J Palen, E Parners & G Apor This study focuses on the fabrication and the Maximum Moment Capacity of a Ferrocement beam. There were three batches with 3 specimens each. The beams were casted vertically by plastering. This study used a cement to sand ratio of 1:3 by volume, and a water to cement ratio of 0.5:1 by weight. It also used two layers of # 16 gage wire mesh kept constant on each batch. Tension bars of 8 mm DRB were used, the number of which increases by one on each batch. Nine specimens of 200mm x 200mm x 3000mm hollow box beam with a 25 mm thickness were casted. The Standards and Procedure for each of the beams were based on the ASTM Standards and on the article by J.P. Hartog. The testing of the beam was done after the 28th curing day period, and was conducted to failure in order to determine the Actual Moment Capacity of the design beam. The results show that Maximum Moment Capacity or Flexural Strength of the fabricated Ferrocement beams did not go below the calculated ultimate moment capacity for office occupancy of 5.3792 KN-m. This means that the beams are safe for use as floor joist beams in residential and commercial structures.

3 and 4 pieces), constant dimensions of 0.2 x 0.2 x 3m-span, wall thickness of 0.025; 2. Determine the flexural strengths and corresponding deflections of the Ferrocement hollow box beams; 3. Design an equivalent conventional reinforced concrete beam based on the flexural strength and cross sectional area of the Ferrocement box beam; and 4. Compare the cost between the Ferrocement box beam and the equivalent conventional beam. The test for the Ferrocement beams will focus on their flexural capacity and corresponding deflection. Shear and torsional capacities are not included. The study does not explore the use of Ferrocement as column, slab, wall and roofing material. The cost estimates include only the material cost. MATERIALS AND METHODS Fine sand, cement and water are mixed to produce the mortar. Standard sieves are used to determine good quality grading of sands appropriate for Ferrocement construction. Ten to fifteen percent should pass through #100 sieve and 100% through the #8 sieve. Deleterious materials are removed from the sand and mortar mixture. The conventional mix of one part cement to three parts sand by volume (Hartog, 1996) is adapted for the cement mortar. A slump test according to ASTM C143 is performed to ensure a good dry mix. Compressive Strength of the cement mortar is also determined according to ASTM C147. Deformed Round Bars with 8mm diameter each are used as main reinforcement. Yield strength of the bars is determined using the Universal Testing Machine following the procedures of ASTM A970. Gage 16 wire mesh with opening is used as wall reinforcement. The group designs a Ferrocement hollow box beam having the dimensions of 0.2 x 0.2 x 3m long with a thickness of 0.025m. Since the beam is plastered and held vertically, forms are constructed for the beams. Scaffolds are used in order to support the forms. The specimens is cured in 28 days achieve its maximum strength. The researchers designed a conventional beam based on the actual Ferrocement flexural strength and cross sectional area, which then be compared in terms of cost per beam. The flexural strength of the Ferrocement beam was evaluated based on the NSCP provisions for the residential type of occupancy.

OBJECTIVES OF THE STUDY The general objective of the study is to promote ferrocement as an alternative flexural member for sustainable low-cost housing. Specifically, the study aims to: 1. Cast a Ferrocement flexural member of a hollow box section with varying numbers of tension bars (2,

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Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

Figure 2 Beam Setup

Beam Set up A. For Calibration 1. Set the beam as simply supported beam. 2. Measure the unsupported length and set the dial gauge at its midspan for deflection reading. 3. Prepare sand bags weighing 25 kg/bag. 4. Gradually load the bags into the beam at 50 kg per batch at 5 batches. 5. Record reading to compare result with UTM Reading. B. Data collecting procedure 1. Record time of testing. 2. Set and install the dial gauge on innovative compression machine. 3. Set the beam into the compression testing machine to be loaded at the mid-span. 4. Gradually load the beam at every 1mm deflection and record gauge reading. 5. Check for micro cracks and record gauge reading. 6. Continue loading until complete failure is achieved. 7. Record the force and its corresponding deflection 8. Record finishing/ending time of testing 9. Set another sample beam for another deflection testing. RESULTS AND DISCUSSION Table 1 shows that all of the results are at the 5 kN mark. It means that batch 1 has the greater average compared to batch 2 and 3 since all 3 batches have the same moment capacity even though that batch 2 and 3 have much more tension bars compared to batch 1. From the calculated actual As, batch 1 has an

area close to the actual As. This would also mean that batch 1attained the Balanced Condition wherein the top fiber compression cracked and simultaneously the tensile bars yielded in which the full capacity of the bars was used. While batch 2 and 3 are already over reinforced, compression failed without the tensile yield. The computed conventional beam dimensions are all the same since the given area is the same, as shown in Table 2. The computed As of the Conventional beam are checked using the Software Gear to ensure correct and accurate calculation. Except the Moment capacity, the values are bigger compared to the Ferrocement beam. The fc is 12.7 higher compared to the Ferrocement fc, since the fc of the conventional beam is 20.7 MPa. This is based on a Class A mixture which is commonly used in the actual process. The fc of the Ferrocement is only But even with these considerations, all of the As of the Conventional beam are around to two 10 mm bars. They are bigger compared to the Ferrocement beam reinforcement. The computed As yielded on the design beam since the group used the tensile strength data that the group achieved on the tensile strength test. CONCLUSION The study was successful in fabricating and determining the flexural strength of the Ferrocement box beam. Even though the Ferrocement beam was supposedly designed for sustainable housing, the results showed that the calculated actual moment of the Ferrocement Beams is good for use as floor joist beams for residential, office and commercial occupancy. The Ferrocement box joist can be applied on residential and commercial occupancy with a one meter spacing base on the minimum live load for residential and commercial occupancy as stated in the National Structural Building Code of the Philippines. The Ferrocement box joist has an average of 11 kg, which is lighter compared to the designed reinforced concrete beam. The strength to weight ratio of the Ferrocement box joist is greater compared to that of the conventional beam. Based on the material cost comparison between the Ferrocement box joist and the designed conventional beam, the Ferrocement is less expensive. Its use can save on gravel and scaffolding costs. Using Ferrocement materials adds an economic advantage in saving general costs in construction. Its light weight feature would mean an increase in workability and transportation, resulting in a fast-paced construction. The researchers acknowledge the possibility of incurring errors such as machine errors since the machine used for testing has not been calibrated for a long time and its dial

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Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

reading available is 500 pounds per tread. Such machine error may affect the reading of the actual moment capacity or flexural strength of the Ferrocement beam. However, the researchers can check the accuracy of the machine through calibration using the point loading at the mid-span with the corresponding deflection of the Ferrocement beam. 2.6 Premature failures in plate bonded strengthened RC beams with an emphasis on premature shear M. Z. Jumaat, M. A. Rahman*, M. A. Alam and M. M. Rahman The aim of the present study is to review the performance of plate bonded flexurally strengthened reinforced concrete beams. This paper also describes the methods and materials used for flexural and shear strengthening of reinforced concrete beams and weaknesses of plate bonded systems. The plate bonding method often has some serious premature debonding failure which can be classified as plate end debonding (end peeling), tension delamination and premature shear failure due to insufficient shear reinforcement. Premature failures must be prevented in order to utilize the full flexural capacity of flexural strengthened reinforced concrete beams. Premature shear failure is one of the major concerns of the flexurally strengthened reinforced concrete (RC) beams. Hence, proper design of external shear strengthening system is required for eliminating premature shear failure of flexurally strengthened RC beams. The review focuses on the possible model and design guideline available in the literature for eliminating premature failures. The paper also discusses a probable approach to eliminate premature shear. Material and methods used for flexural strengthening Using ferrocement laminate Ferrocement is a thin composite material which is composed of cement mortar reinforced with uniformly distributed layers of continuous, relatively small diameter, wire meshes. The report containing the design and construction of ferrocement is published by the ACI committee 549 (ACI549-88R; ACI549.1-88R, 1988). Ferro-cement, being of the same cementitious material as reinforced concrete (RC), is ideally suited as an alternative strengthening component for the rehabilitation of RC structures (Paramasivam et al., 1998). It possesses higher tensile strength to weight ratio and a degree of

toughness, ductility, durability and cracking resistance that is considerably greater than those found in conventional cement based materials. The use of ferrocement was first introduced by Roumaldi (1987) and Iorns (1987) in the early 1980s. The ferrocement was utilized for its toughness, cracking resistance and ease of application to fit the difficult contours of structures. Initial investigation for using ferrocement laminate as strengthening components for the repair and strengthening of RC beam was carried out by Andrews and Sharma (1988). Nassif et al. (1998) studied the behaviour of ferrocement concrete composite beams and the required area of steel mesh in the ferrocement layer to ensure overall adequate flexural response in comparison with a similar concrete section. For strengthening beams in flexure pre-fabricated ferrocement reinforcements were attached onto the beams tension face before the ferrocement matrix was cast to complete the laminate. All the beams strengthened without surface roughening (Ong et al., 1992) and without using the mechanical shear connectors (Paramasivam et al., 1994), exhibited localized horizontal cracks along the concrete/ferrocement interface and severe delamination of the ferrocement at failure. CONCLUSION The summary of the failure modes of flexurally strengthened RC beams can be classified as: (1) Premature debonding failure which can be plate end debonding or end peeling (beams failed just after or after reaching tensile reinforcements yield strength without showing any ductility value) (2) Tension delamination at midspan and (3) Premature shear failure due to insufficient shear reinforcement. End peeling occurs due to shear and normal stress at the end of the plate which can be minimized by using proper end anchor. Tension delamination occurs when a plate spans across flexural or shear crack, it can be seen that wherever a flexural crack touches the plate, a debonding crack would form along the edge of the plate. Researchers have found that debonding in the mid-span can be minimized by controlling the strain of CFRP laminate. Though researchers have found a solution to eliminate end peeling using appropriate end anchor, research on tension delamination and premature shear failure of flexurally reinforced strengthened RC beams is still limited. In order to utilize the full flexural capacity of strengthened beams all of the stated failure modes should be prevented. Sometimes premature shear failure becomes crucial when the shear reinforcement

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Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

present is no longer sufficient due to the increase in flexural capacity which increases shear forces. Hence, this excess shear must be accounted for to ensure that the strengthened beam does not fail by premature shear before attaining its full flexural capacity. 2.7 Ferrocement box sections-viable option for floors and roof of multi-storeyed buildings A. Kumar, Structural Engineering Division, Central Building Research Institute, Roorkee A 5m x 9m size interior panel of a framed structure has been designed as beam-slab construction, flat slab construction and using ferrocement box sections for 5 kN/m2 live load. The self-weight, floor/ roof height and cost of these options have been compared. It is found that the flat slab option is comparable in weight to the beam-slab option, about 58.2% less in floor height and 17.7% costlier than the conventional beam and slab construction. The ferrocement box section alternative is found to be 56.2% less in weight, comparable in floor height and 15.6% cheaper than the beam - slab construction. The ferrocement box sections being light in weight need less strong supporting structures. Being a precast product, they also increase speed of construction and can be used in bad weather conditions. TESTING OF FERROCEMENT BOX-SECTIONS A ferrocement box specimen (shown in Figure 6) was tested over an effective span of 3000mm and failed at an imposed load of 7.86 t due to snapping of wire meshes in the bottom flange at the mid span. The same model was also analysed by the finite element method. Its analytical and experimental deflections at mid span and quarter span are shown in Figs. 7 and 8 respectively. A capacity check based on the Limit State of collapse shows that this section can be used over 5740mm effective span. The predicted maximum crack-widths based on the expression given by Logan and Shah (1973) [12] and Naamans equation (1979) [40] along with experimental values are plotted in the Figure 9. Assuming that the creep coefficient increases the crack-widths by 60 percent on an average, the failure load at a crack width of 0.19 mm (0.3mm/ 1.6) was 5.70 t. By applying the serviceability criterion for crack-width, the same section can be use for an effective span of 5630mm. The deflection limit of span/ 250 including the longterm effects of creep and shrinkage based on crack control has already been taken into account. The deflection, span/ 350 or 20mm that is permitted in

RCC elements after the construction of partitions and finishes is, however, not exceeded. This section can be used safely over an effective span of 5630mm as a one way element. In the present study, it is used over an effective span of 5000mm. This section can be used economically as an alternative even to oneway slabs (for any length beyond 5500mm) of 5500mm width, while the reinforced concrete options would need to be redesigned with an increased depth. The two-way slab is found to be the thinnest but costlier. Therefore, in medium span floors, the ferrocement box section is probably the best choice.Ferrocement as a material offers savings in maintenance cost and increases the speed of 580 A. Kumar construction. Immediate repairs are also possible in case of any damage. Ferrocement products offer impermeability or in other words the rate of penetration of water is very low. This slow rate of penetration of moisture increases the threshold time for the start of corrosion and also the durability of the structural component is enhanced.

CONCLUSIONS 1. The ferrocement box sections supported on R.C.C. beams are found to be 15.6% cheaper than the beam and slab construction, while the flat slab option is 17.7% costlier. 2. The ferrocement box section is found to be 56.2% lighter than the beam and slab construction, while the two reinforced concrete options are comparable in weight. The use of ferrocement box sections will economize on the supporting structure also due to their lower self weight. 3. The ferrocement box sections supported on R.C.C. beams and the beam slab construction have comparable floor depths (910mm), while the flat slab option is smallest in floor depth (380mm). 4. At service loads, ferrocement shows a large number of cracks of smaller crack-width compared to few wide cracks in reinforced concrete.

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Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

5. Being a precast product, use of ferrocement box section will increase the speed of construction and also make the construction of buildings feasible in bad weather conditions. 6. The use of ferrocement box sections with higher ductility will make the structure less prone to seismic damage. 2.8 Structural behaviour of ferrocement arched beam with inverted u-section Mohsen Ahmad Hassan Habil Al-Matteen The main aim of this study was to investigate the behaviour and ultimate strength of ferrocement arched beam with inverted U-section under flexural load. The main parameters considered in the present investigation were, cement sand ratio, number of wire mesh layers, support conditions and thickness of the cross section. A total of five full scale arched beam with inverted U-section were constructed and tested under two patch loads on the middle of the arched beam. The behavior of models was observed by reading the deflection at mid-span and observed the crack patterns. The theoretical analysis results for the arched beam with inverted Usection were predicted by finite element method by using a computer program called "ANSYS version 5.4". From the experimental and theoretical results obtained, it was found that the behavior of ferrocement arched beam is linear up to first cracking load and still linear with smaller slope up to about (75-80 %) from the ultimate load. The load-deflection curve at mid span of the arched beam may be idealized by bilinear curve. Increasing number of layers of wire mesh (from 2 to 3) tend to increase the ultimate load by (5% to 13.9%). While changing the support condition from pined-pined to fixed-fixed tends to increase the ultimate load by (13% to 13.6 %). Increasing cement sand ratio (from 1:3 to 1:2) tend to increase the ultimate load by (9% to 17.3 %), and increasing the thickness of U-section of arched beam (from 20 mm to 30 mm) tend to increase the ultimate load by (9.5 to 11.1%). Experimental Work: In order to study the structural behaviour and ultimate strength of ferrocement arched beam with inverted U-section having actual dimensions which can be used for pre-cast purpose when subjected to flexural load, a total of five full scale ferrocement arched beam with inverted U-section were cast and tested in the present study. A pilot arched beam with inverted U-section was made first to gain experience of the use of ferrocement material and to establish a

method of casting the mould and to assess its suitability for the construction of arched beam with inverted U-section. Preparation of the Arched Beam: The longitudinal and transverse skeletal were cut according to the mould size, after that this skeletal were connected together by a small diameter wires. The frame of the skeletal was covered by a number of square wire mesh according to its case to form a cage. After cleaning and oiling the mould, the cage was placed on the mould. All materials required for each beam were weighted and mixed by a mechanical mixer. Firstly the sand and cement were mixed for one minute, and then the water was added and mixed for two minutes. The mortar was forced into the mesh reinforcement cage with trowels. Mortar control specimens were taken from the same mix. The arched beams and the control specimens were cured throughout (28 days).

Conclusions: From the experimental and theoretical results the following conclusions can be drawn: 1. The behaviour of ferrocement arched beam with inverted U-section is linear up to first cracking load and still linear with smaller slope up to about (7580%) from the ultimate load. The load-deflection curve at mid span of the arched beam may be idealized by bilinear curve. 2. Increasing number of layers from 2 to 3 layers tend to increase the ultimate load by (13.9% and 5%) in experimental and theoretical respectively. 3. Change the support condition from pined-pined to fixed-fixed tend to increase the ultimate load by (13% and 13.6%) in experimental and theoretical respectively. 4. Increasing cement sand ratio (CSR) from 0.33 to 0.5 tend to increase the ultimate load by (9% and 17.3%) in experimental and theoretical respectively. 5. Increasing the thickness of U-section of arched beam from 20mm to 30mm tend to increase the

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Analysis and Design of Ferrocement beams an Experimental Study

Varun Deogaokar1 Prof. Gaidhankar 2

timate load by (11.1% and 9.5%) in experimental and theoretical respectively. 6. Increasing the arise of normal crown of arched beam from zero (straight beam) to (0.25 m) and (0.5 m) tend to increasing the ultimate load by (60%) and (13%) respectively. 7. The theoretical solution of finite element method by using the ANSYS program is a good tool for represent the behaviour of the ferrocement arched beam with inverted U-section. 3. Analysis and Design of Ferrocement beams an Experimental Study Varun Deogaokar1 Prof. Gaidhankar 2 Stage I The study is primarily aimed at investigating experimentally and analytically 1. The behavior of ferrocement beams under two point loading with following parameters for flexure and shear. - Change in cross-sectional dimensions - Change in length - Change in reinforcement ratio The behavior of ferrocement beam for varying aspect ratio. The plastic analysis of ferrocement beams.

Guide for the Design, Construction and Repair of Ferrocement Reported by ACI Committee 549 Experimental and Analytical Model of Ferrocement Beams research paper by Boshra Aboul-Anen, Ahmed El-Shafey, and Mostafa El-Shami in International Journal of Recent Trends in Engineering, Vol. 1, No. 6, May 2009

2. 3.

The results obtained will aid the designer and manufacturer the design procedure, method of construction for beams that is consistent with the level of risk specified or intended. As newer applications of ferrocement are introduced in market, many interesting problems will be posed so we will have to find solutions to these problems by searching new design techniques and method of constructions.

References: Research Needs in Ferrocement Technology by Dr.P.N.Divekar, President, Ferrocement society, Pune Flexural strengthening of reinforced concrete beams use in ferrocement laminates, Journal of ferrocement Vol.22

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