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DEFINITION OF FERROCEMENT
ACI 549 R definition Ferrocement is a thin walled
reinforced concrete commonly constructed of
hydraulic mortar reinforced with closely spaced layers
of continuous and relatively small size wire mesh. The
mesh may be made of metallic or other suitable
materials.
CONSTRUCTION PROCEDURES
Four Major Stages of Construction- Placement of wire mesh in a proper position,
Mortar mixing, Mortar Preparation and Curing
Preparation and Placement of wire mesh:
Wire mesh usually the main reinforcement except for highly stressed structures.
Galvanised wire mesh is preferable
No. of layers of wire mesh usually vary from two to eight.
Square woven wire meshes-Ensure Isotropicity.
CONSTRUCTION PROCEDURES
Mortar Preparation
Consistent design strength- Usually 1:2 cement to
sand and a w/c ratio of 0.6
High Strength, High Performance Mortar-reduced
workability-Use of mineral and chemical admixtures
Hand mixing-Most of the times.
Plastering
Most critical phase-Plastering by hand, fingers and
trowels are used.
Single stage and Two stage techniques.
CONSTRUCTION PROCEDURES
Curing
Curing to promote hydration of cement under controlled temperature.
Moist Curing- keeping mortar in contact with water for at least 10-14 Days.
Spraying of flooding by covering surface with wet sand or earth etc;
Impermeable Cover Curing- Water proof paper-prevent evaporation of water.
Steam Curing- After 4 to 5 hours of casting- 70 degrees temperature.
ROOFING
Very
Light-Weight Roofing
Easily transportable
Same strength as RCC
Very High Water Proofing Quality
No Plastering for Ceiling
Roof ready in just 3 days
20-40% cheaper roofs; 5-10 times
more strength to weight ratio;
Easier to install; 10 times faster
construction; 75% lighter than
conventional RCC slabs
BEAMS
Very Light-Weight Beams
Easily transportable
5 times higher strength to weight
ratio w.r.t. RCC
No Plastering required
Beams Installed in Just 3-Days
15-25% cheaper beams; 5-10
times more strength to weight
ratio; Very Easy to install; 10
times faster construction than
conventional RCC; 75% lighter
than conventional RCC
WALLING
COMPARISON OF FERROCEMENT
WITH OTHER CONVENTIONAL
ELEMENTS
PROPERTIES OF FERROCEMENT
TECHNOLOGY
PRODUCTION SYSTEM
Semi-Mechanised System
Well laid out yard with clear flow / movement required
1 Machine + 6 Moulds per 8 hours shift
Vibrating System: Table Vibrator for improved consolidation
1 Expert + 3 to 6 labour required
Concrete Mixer preferred. Hand mixing acceptable.
8 hours normal production time required
Casting time per channel: 15 minutes only
Curing Period as per concrete code books
Upto 24.3 rm of FRC ready in 8 hour shift with basic inputs
Reduces the trouble of laying at site. Near-perfect production
system! Near-perfect product!
VOLUME FRACTION
Volume Fraction of reinforcement is the ratio of the volume of
reinforcement to the volume of composite
Vr = Volume Fraction = Vreinforcement/Vcomposite
Vr = N dw2
----------- (1/DL+1/DT)
4h
N - Number of Layers,
d
w
DT
dw Diameter of Wire
DL
Vr = N dw2
for square mesh
----------2hD
EXPERIMENTAL PROGRAM-FCRC
0
4
Details of
Reinforcement
FERROCEMENT-LABORATORY MODELS
Mould
Fabricated mesh
LONGITUDINAL SECTION OF
COMPRESSION-COMPRESSION
CT
TC
TT
CC
COLUMN FAILURES
SHEAR FAILURE
FERROCEMENT JACKETING
PEELING OF COVER(OPTIONAL)
CASTING OF COLUMN
DETAILS OF TESTING
Column
FrReactameion
Bsi
draelforce
L
at
e
alStParess
1.Axi47M
Specimen
Asi
draelforce
L
at
e
Footing AnchorBolts
0
B
A
C,D
SIDE
Card Scope
Strain
gauge
Bridge
Box
Dial
gaug
e
Bridge
Box
AMP
AMP
Signal
Conditioner
Strain
Gauges
Displacement
meters
A/D
A/D
-40
200
100
100
0
-20
0
-100
20
40
60
-60
0
-20
0
-100
-40
-200
-100
-150
20
40
60
-60
-40
-20
-100 0
40
60
100
100
20
40
-200
Lateral Displacem ent(mm )
60
Load(kN)
200
-60
-40
0
-20
0
-100
-20
10
20
30
-200
LOAD-DISPLACEMENT
ENVELOPES
Displacem ent(m m )
200
-30
-200
0
-20
0
-100
20
-40
0
-10-50 0
100
Load(kN)
Load in kN
50
100
Displacem ent(mm )
Load(kN)
100
200
-200
-40
150
200
-20-100 0
Control
6 Layers
4 Layers
200
-60
60
-40
40
-200
-60
20
Load(kN)
-60
200
L oad (kN)
Load(kN)
20
40
-200
Lateral Displacem ent(m m )
60
40
Load in kN
Load in kN
50
0
-800 -400-50 0
0
400
-150
100
400
-100
-150
-100
50
0
-800 -400-50 0
400
800
-100
-200
-150
Micro Strain
Micro Strain
6 Layers Ferrocement
150
100
50
100
-800 -400
0
-50
200
Load in kN
150
-200
Micro strain
LONGITUDINAL REINFORCEMENT
6 Layers Ferrocement
Control Specimen
150
200
100
50
0
-500
-50
500
1000
1500
2000
Load(kN)
Load(kN)
100
0
-200
-100
100
-100
-100
-200
-150
MicroStrains
MicroStrains
TRANSVERSE REINFORCEMENT
200
300
400
200
200
150
150
Load(kN)
Load(kN)
LOAD-DISPLACEMENT DIAGRAMS
100
50
0
-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80
-50
Disp(m m )
-100
-150
-200
RCC S1-100kN
-200
FERROCEMENT RETROFITTED
F1-100kN
200
200
150
150
SHEAR FAILURE OF
100
RCC SPECIMEN
Load(kN)
Load(kN)
50
0
-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80
-50
Disp(m m )
-100
-150
100
50
0
-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80
-50
Disp(m m )
-100
50
0
-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80
-50
Disp(m m )
-100
-150
-150
-200
RCC S2-150kN
-200
FERROCEMENT RETROFITTED
200
200
150
150
Load(kN)
Load(kN)
100
100
50
0
-80 -70 -60 -50 -40 -30 -20 -10 0
-50
-100
10 20 30 40 50 60 70 80
Disp(m m )
-150
-200
RCC S3-200kN
F2-150kN
100
50
DUCTILE FLEXURAL
0
-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 FAILURE OF FERROCEMENT
-50
Disp(mm )
JACKETED SPECIMENS
-100
-150
-200
FERROCEMENT RETROFITTED
F3-200kN
3500
1400
3500
1200
3000
1200
3000
1000
2500
800
2000
600
1500
400
1000
200
500
0
1000
2500
800
2000
600
1500
400
1000
200
500
60000
55000
50000
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
Loading Cycle
1200
3000
1000
2500
800
2000
600
1500
400
1000
200
500
15000
14000
13000
12000
11000
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
Loading Cycle
60000
55000
50000
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
Loading Cycle
Dissipated Energy(kNmm)
Dissipated Energy(kNmm)
15000
14000
13000
12000
11000
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
3500
Loading Cycle
Cumulative Energy(kNmm)
Dissipated Energy(kNmm)
Loading Cycle
1400
Cumulative Energy(kNmm)
Cumulative Energy(kNmm)
1400
4000
Dissipated Energy(kNmm)
4000
Dissipated Energy(kNmm)
1600
Cumulative Energy(kNmm)
4000
Dissipated Energy(kNmm)
1600
1600
Cumulative Energy(kNmm)
15000
14000
13000
12000
11000
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
60000
55000
50000
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
Loading Cycle
Cumulative Energy(kNmm)
NUMERICAL MODEL
Specimen
RCC Column
Displacement(m
m)
0
H/2
Stress (MPa)
H/2
Result
4.60
3.00
4.2
7.1
Expt.
4.53
2.88
3.6
6.0
Num.
4-Layered
Ferrocement
1.72
1.69
1.19
1.08
2.7
2.4
5.0
4.5
Expt.
Num.
6 Layered
Ferrocement
1.39
0.84
1.9
2.4
Expt.
1.37
0.81
1.4
2.1
Num.
Cost(Yen/m2)
Carbon Fiber
10,000-20,000
Aramid Fiber
10,000-15,000
Glass Fiber
5,000-7,500
Ferrocement
200-300
Use of Ferrocement
1200
Number of Projects
Material
1023
1000
762
800
600
400
425
256
200
0
1990
1995
2000
Year
2005
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