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Journal of Green Engineering (JGE)
Volume-10, Issue-1, January 2020
Study on Behavior of Sustainable Ferrocement Overlay Beam using M-Sand
1S.Christi,
2A.Arunraj,
3V.Venkatesan,
4R.Logaraja
1Assistant Professor, Faculty of Civil Engineering, St. Joseph College of Engg.,
Chennai, India. E-mail: [email protected] 2Assistant Professor, Faculty of Civil Engineering, Easwari Engg College., Chennai,
India.E-mail: [email protected] 3Assistant Professor, Faculty of Civil Engineering, University College of Engg.,
Ariyalur, India E-mail: [email protected] 4Assistant Professor ,Faculty of Civil Engineering, Sethu Institute of Technology,
Kariapatti, India. E-mail: [email protected]
Abstract
The study investigates about the suitability and sustainability of usage of
Manufacturing Sand (M-Sand) of ferrocement concrete beams with including
and excluding of reinforcement. To achieve this, investigation consists of
beams with the dimension of 300mm x 150mm x 1000mm with stable
precast formwork of thickness of about 25mm are made. The reinforced
concrete beams of the above mentioned dimension are casted for
conventional concrete specimens. A welded wire mesh of single layer is used
as reinforcement in the beams. After casting, the beams are undergone with
curing for 28 days and testing was conducted under two point loading
concept. On comparison of the test results it is found that, the ferrocement
overlay beam possess more strength, better resistance against cracking and
good energy absorption. Hence, ferrocement overlay beam satisfy the higher
serviceability limits.
Keywords: Sustainable Ferrocement, M-Sand, Reinforcement, RC beam,
Resistance.
Journal of Green Engineering, Vol. 10_1, 144–160. Alpha Publishers
This is an Open Access publication. © 2020 the Author(s). All rights reserved
145 S.Christi
et al
1 Introduction
Now days, Civil Engineering is moving through with an advanced
development techniques and construction methods. Since increase in
demand of construction materials and heavy weight of conventional
concrete this affects the development. Trying to overcome these causes M-
sand is used instead of River Sand and Ferrocement concept is applied to
conventional concrete. This present work focus on the ferrocement beam
jacketing by using M-Sand[1].
2 Literature Study
Ferrocement is a blended component consists of cement mortar that
impart tensile strength and steel fibers in the pattern of wire mesh as
reinforcement which deformability to the material. Because of the
distribution of small mesh reinforcement over entire volume of the mortar,
very high resistance against cracking is obtained, besides improvement in
many engineering properties [1]. View to enhance the shear and flexural
capacity to restrain the cracking and deflection in the concrete structure
strengthening was recommended. For that reason various types of materials
have been used from early age. Implementation of repair works with
ferrocement in the early 1980’s contributes more on the repair of lining
membranes in the liquid storage, pipeline structures, etc.
Study made with the usage of ferrocement for repair works and
strengthening also conducted. Some of the applications of ferrocement are
the Tanks, Containers, Silos, Floors and Roofs, Pipes & Sewer lines etc. [3]
Ferrocement is a product in which layers of metallic or non metallic weld
mesh are used in reinforcing the structural members. Appropriate steel /
weld mesh size is selected such that adequate bonding is achieved between
matrix and reinforcement. Durability of the concrete is increased through
ferrocement. The use of mesh in the concrete helps in increasing a tensile
strength to a modest level. The ferrocement as a stiff material which can
hold the heavy concrete helps in places of form work.
This work is aims to analyze the strength of the ferrocement jacketing
with comparative study of river sand and M-sand. The amount of deflection
that could be taken in the beam until outer crack also tested.
3 Material Requirements
The constituent materials of ferrocement for this work are wire mesh
reinforcement, smaller size aggregates, cement mortar and admixtures.
Study on Behavior of Sustainable Ferrocement Overlay Beam using M-Sand 146
3.1 Matrix
The constituents in the ferrocement include the binder particles as
Portland cement, fine aggregate as M-sand and water. Admixtures may be
suitably used based on the purpose of the product. The Quality of the Fine
aggregate passes through American Standards ASTM No. 8 sieve (Indian
Standards IS size of 2.36 mm) sieve. The governing material in controlling
the structural behaviour of ferrocement is the matrix. Selection of materials
for the matrix and the placing and also the curing should be done with
caution.
3.2 Cement
Cement factors are normally higher in ferrocement than in reinforced
concrete. The cement confirmed with ASTM C 150, ASTM C 595, or with
an equivalent standard of IS codes. The quality of cement should be
maintained as prescribed by codal provisions. [5]
The most commonly used cement type is designated as Type I in ASTM
C 150. Type II cement generates less heat during hydration and is also
moderately resistant to sulfates. Type III is rapid-hardening cement which
acquires early strength more rapidly than Type I cement. Type IV is low-
heat cement used for mass concrete and is seldom considered for
ferrocement. Type V is sulfate-resisting cement used in structures exposed
to sulfate.
3.3 Ground Granulated Blast Furnace Slag(GGBS)
In GGBS, main constituents like oxides of magnesium, calcium, aluminium
and silicon di-oxide. It is produced by the process of quenching of molten
iron slag then dried and powedered into a fines to obtain a glassy granular
product. The combination of ordinary Portland cement and/or other
pozzolanic materials with the GGBS is used to make durable concrete
structures. While GGBS used obviously there will be reduction of hazard due
to reaction of alkali-silica gives resistance to access of chloride. . Physical
properties of GGBS have been presented in Table 1 and also shown in Fig 1.
[2]
147 S.Christi et al
(a) (b)
Fig 1 GGBS (a) 50 Kg bag (b) powder form
Table 1 Physical Properties of GGBS
The aggregates are the key constituents of the concrete which influences
the strength, density and other properties. In this work Local aggregates
comprising of 20 mm and 12mm coarse aggregates and fine aggregates
were used in saturated surface dry state, were used. The coarse aggregates
and the fine aggregate was crushed granite type aggregate of size less than
5mm commonly called as M-sand (manufactured sand) were used. Different
types of aggregates have obtained locally for experimental work is
discussed below.
3.4.1 Fine aggregate (M-Sand)
M-sand is used as fine aggregate in the experimental work and is
obtained from the local suppliers near Sriperumbudur in Chennai which is
shown in Fig 2. The physical properties of fine aggregate (M-Sand) have
been done and presented in Table 2.
S.No Physical properties Test Result
1 Specific gravity 2.85
2 Physical form Powder
3 Size (Micron) 0.3
4 Colour White
5 Blaine fineness 400 m2 /kg
6 Density 2800 kg/m3
Study on Behavior of Sustainable Ferrocement Overlay Beam using M-Sand 148
Fig 2 M-Sand as fine aggregate
3.4.2 Coarse aggregates
In this study, coarse aggregates of size between 12 mm and 20 mm
conforming to specifications as given in IS: 383- 1970 is used. Specific
Gravity (SG) of aggregates is found through Pycnometer test. Sieve analysis
has been done to find the fineness modulus (FM) of aggregate. The physical
properties of the coarse aggregate of size 12mm and 20mm have been
displayed in Table 2 respectively [2].
Table 2 Physical properties of aggregate
S.No Items Fine Aggregate Coarse Aggregate
1 Type Crushed stone (M-
Sand)
Crushed
stone Crushed stone
2 Particle Size
(Maximum) 4.75 mm 12mm 20 mm
3 SG-Specific gravity 2.65 2.67 2.71
4 FM-Fineness modulus 3.33 6.80 7.68
3.5 Water
Clean Portable water (pH 6.5 – 7) free from organic and inorganic
substances was used in the preparation of ferrocement concrete.
149 S.Christi et al
3.6 Wire Mesh Reinforcement
The objective of providing wire mesh as reinforcement is to impart
tensile strength to concrete and resist against cracking. It also supports in
holding the ferrocement concrete together in wet state. The commercially
available weld meshes are as shown in Fig 3. In this study, 2.5mm thick steel
rods welded into square mesh of size 25mm x 25mm made were used.
Fig. 3 Different shapes of Wire Mesh
4. Experimental Investigation
The main aim of this work is to study the flexural strength of concrete
beams with ferrocement jacketing. The experimental program consists of
casting and testing of three RCC beam of size 150mm × 300mm ×
1000mm. The aim of this work was done by the following tasks,
Specimen 1 - Control beam.
Specimen 2 - Beam jacketing with river sand. (Core M- sand).
Specimen 3 - Beam jacketing with M- Sand. (Core M-sand)
4.1 Mix Design
Using the concept of ferrocement, Beam jacketing with river sand and
M-sand Specimens at the size of 1000mm x 150 mm x 300mm are casted. A
control beam is also made at the size of 1000 mm x 150mm x 300mm and
all three beams is to be tested and all the values are to be compared with
each other to check flexural strength and deflection [2] [5].
Study on Behavior of Sustainable Ferrocement Overlay Beam using M-Sand 150
• For Control Beam ( M25 -mix ratio 1:1.5:3 )
1. Cement = 20.45 kg.
2. M-Sand = 30.68 kg.
3. Aggregate (12mm) = 33.75 kg.
4. Aggregate (20mm) = 27.61 kg.
5. Reinforcement at both Tensions& Compression zone = 4nos of 12mmΦ
6. Stirrups = 6nos of 6mm Φ150mm c/c
7. Water cement ratio = 0.45
• Beam Jacketing with River Sand
Ferrocement (mix ratio 1:2)
1. Cement = 9.34kg
2. GGBS = 2.33kg
3. River sand = 23.33kg
4. Water cement ratio = 0 .4
Core material (M25 - mix ratio 1:1.5:3)
1. Cement = 12.5kg
2. M-sand = 18.75kg
3. Aggregate (12 mm) = 20.5kg
4. Aggregate (20 mm) = 17kg
5. Reinforcement = 2nos of 12mmΦ (Tension Zone)
6. Water cement ratio = 0.45
• Beam Jacketing with M-Sand Ferrocement (mix ratio1:2)
1. Cement = 9.34kg
2. GGBS = 2.33kg
3. M-Sand = 23.33kg
4. Water cement ratio = 0.4
Core material (M25-mix ratio 1:1.5:3)
1. Cement = 12.5kg
2. M-sand = 18.75kg
3. Aggregate (12 mm) = 20.5kg
4. Aggregate (20 mm) = 17kg
5. Reinforcement = 2nos of 12mmΦ (Tension Zone)
6. Water cement ratio = 0.45
151 S.Christi
et al
4.2 Preparation of the Mortar
To prepare a ferrocement beam, mortar required for jacketing the G.I
Mesh is done. Cement and GGBS are taken in the ratio of 0.8:0.2. This
binder is then mixed with fine aggregates on the ratio of 1:2. Water content
as per the W/C ratio is added to this dry ingredients of concrete to get a
perfect mortar which is shown in Fig 4.
Fig.4 Preparation of ferrocement mortar
4.3 Casting of the beam
A G.I mesh of size 900 mm x 165mm is placed inside the mould and the
cement mortar mix is placed. This set up kept without disturbance for 24
hours. Then, the beam is casted by placing the M25 concrete inside the wire
mesh. The beam is then allowed for curing after the demoulding. Mould and
placing of wire mesh for Beam jacketing is shown in Fig 5and Casted
Sample is shown in Fig 6.
(a)
Study on Behavior of Sustainable Ferrocement Overlay Beam using M-Sand 152
(b)
Fig 5 a) Mould for casting of beam b) Mesh gauge
Fig 6 Casted sample of beam
4.4 Curing of the beam
The beam is cured by wrapping the beam with wet gunny bags. When
the gunny bag dries, it wetted again by pouring the water. This is generally
done once in a day. Curing of the beam is shown in Fig 7.
Fig 7 Curing process of the casted Beam
153 S.Christi
et al
The above Manufacturing Process is used for casting the all three
Specimens. Mixing of materials and Quantity is changed according to the
specimen needed.
4.5 Tests on Ferrocement Beam Jacketing
Flexural strength test is carried out to find the flexural strength of
specimen. In this study beam samples were casted and cured in direct sun
light for 28 days. After curing all the three Specimens 1000mm ×150mm
×300mm were tested by using Universal Testing Machine UTM with a
capacity of 1000 kN. [6]
The beam is dividing into three parts with 150 mm on both ends and
700mm in the center and it is marked. The beam is further divided into three
parts in the middle portion to 233.33mm (700/3) and it is marked. Then the
beam is placed on the supports. This beam is tested in two point method.
The beam is placed with the outer length of 150mm at the both ends on the
supports. Then the load is applied on the center of the beam with two
supports on the top. [8]
As the load increases, the deflection is noted for every 10 kN. The
flexural strength of the concrete is then found by 1.5wδ/bd2. The UTM is
shown in Fig 8.
Fig 8 Universal Testing Machine
Study on Behavior of Sustainable Ferrocement Overlay Beam using M-Sand 154
5 Results and Discussions
The results obtained from the experimental study on flexural strength of
ferrocement beam jacketing using river sand and M-sand has been discussed
as follows.
Flexural behavior of the beam is noted for every 10 KN load and
deflection of the beam also compared. From the test, it was known that for
the control beam crack is formed when the load comes to 196 kN and the
corresponding flexural strength and deflection at that point is 8.6 N/mm2 and
3.86 mm respectively. The variation of flexural strength and Deflection
along with load for control beam is shown in Fig 9. The graph was plotted
for the better understanding of result interpretation. From the graph it was
clearly observed that, corresponding to the load flexural strength and
deflection was gradually increased. At the point of 196kN the member loss
its elasticity and started to failure. The failure of beam is shown in Fig 10[8]
[12].
Fig 9. Effect of variation in flexural strength and deflection with load for control
beam (specimen -1)
0.2
7
0.4
2
0.5
1
0.6
0
0.7
1
0.8
6
1.0
0
1.1
0
1.2
3
1.4
8
1.5
8
1.8
0
2.1
2
2.5
0
2.6
4
2.8
8
3.0
0
3.2
0
3.6
3
3.8
6
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
Fle
xtu
ral
Str
en
gth
N/m
m2
De
fle
ctio
n i
n m
m
Load in kN
Loas Vs Deflection & Flextural Strength on Control Beam
Flextural Strength Deflection
155 S.Christi et al
Fig 10. Failure of the specimen
Similarly other two specimens were tested and the results are discussed
for the flexural behavior of ferrocement beam using River sand and M-sand.
It was clearly observed that ferrocement beam with River Sand were loss its
elasticity and started to failure at the load point171.4kN and the
corresponding flexural strength was 8.9 N/mm2 and its deflection was 3.92
mm. For the better observation, results are plotted in a graph to know the
effect of variation of flexural strength and variation of Deflection with
loading using River sand is shown in Fig 11.
Fig 11. Effect of variation in flexural strength and deflection with load using River
sand
Similarly Specimen 3 (M-sand overlaying) was tested and results were
discussed and graphs were plotted for the effect of variation and deflection
0.3
5
0.5
6
0.7
5
0.9
0
1.0
0
1.0
9
1.2
3
1.5
2
1.7
3
1.9
1
2.1
3
2.3
9
2.8
3
3.1
9
3.4
8
3.8
9
3.9
2
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
Fle
xtu
ral
Str
en
gth
N/m
m2
De
fle
ctio
n i
n m
m
Load in kN
Loas Vs Deflection & Flextural Strength on River Sand
Flextural Strength Deflection
Study on Behavior of Sustainable Ferrocement Overlay Beam using M-Sand 156
with increase in loading is shown in Fig 12. It was observed that the
Specimen 3 obtain failure at the loading point 201 kN and the corresponding
flexural strength and deflection were10.4N/mm2 and 4.7 mm respectively.
Fig 12. Effect of variation in flexural strength and deflection with load using M-sand
While comparing the flexural strength of all the three types of specimen,
it was clearly observed that the M-sand jacketing specimen gives higher
strength when compared to other two specimens. Comparison of flexural
strength is shown in Fig 12 and Comparison of Deflection was shown in Fig
13. In the deflection chart which shows that M sand jacketing specimen
withstand large load upto 200kN and undergoes acceptable deflection. [11]
Fig13 Comparison of flexural strength
0.1
7
0.3
0
0.4
1
0.5
0
0.6
1
0.7
6
1.0
0
1.1
5
1.3
2
1.4
8
1.6
5
1.9
2
2.1
2
2.3
4
2.5
8
2.8
4
3.1
5
3.6
0
4.0
8
4.7
0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
Fle
xtu
ral
Str
en
gth
N/m
m2
De
fle
ctio
n i
n m
m
Load in kN
Loas Vs Deflection & Flextural Strength on M-Sand
Flextural Strength Deflection
0.5
1
1.6
2.1
2.6
3.1
3.6
4.1
4.7
5.2
5.7
6.2
6.7
7.3
7.8
8.3
8.9
0.5
1
1.6
2.1
2.6
3.1
3.6
4.1
4.7
5.2
5.7
6.2
6.7
7.3
7.8
8.3
8.8
9.3
9.9
10.4
0.4
0.9
1.3
1.7
2.22.4
2.73
3.3
3.7
4.2
4.75
5.3
5.9
6.3
6.7
7.3
7.9
8.6
00.5
11.5
22.5
33.5
44.5
55.5
66.5
77.5
88.5
99.510
10.511
11.512
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
De
fle
ctio
n i
n m
m
Load in kN
Loas Vs Flextural Strength
River Sand M-sand Control Beam
157 S.Christi et al
Fig14 Comparison of Deflection
6 Conclusions
GGBS based ferrocement jacketing can be produced using technology
and equipment used for the manufacturing of conventional concrete. Using
jacketing in concrete helps to increasing the strength of the beam or column
and it used effectively in repairing structures, increasing the strength of the
deflected structures. From the test, it was known that for the control beam
crack is formed when the load comes to 196 kN and the corresponding
flexural strength is 8.6N/mm2 and deflection at that point 3.86mm
respectively and it is compared with other specimens, while comparing it
was clearly observed that ferrocement beam with River Sand were loss its
elasticity and started to failure at the load point 171.4kN and the
corresponding flexural strength was 8.9 N/mm2 and its deflection was
3.92mm but the ferrocement beam with M-sand were increases its elasticity
and started to failure at the loading point 201 kN and the corresponding
flexural strength and deflection were 10.4N/mm2
and 4.7 mm respectively.
[12]
The strength of the ferrocement jacketed beam with m-sand is high
when compared to that of ferrocement beam with river sand and control
beam which helps in increasing economic status of the structure. It is alkali
resistance when compare to other concrete and the GBS based ferrocement
keeps on increasing the strength of the beam from the day of 28 till 10 to 12
years.
0.35
0.56
0.750.9
11.09
1.23
1.52
1.73
1.91
2.13
2.39
2.83
3.19
3.48
3.89 3.92
0.170.3
0.410.5
0.610.76
11.15
1.321.48
1.65
1.92
2.12
2.34
2.58
2.84
3.15
3.6
4.08
4.7
0.270.42
0.510.6
0.710.86
11.1
1.23
1.481.58
1.8
2.12
2.52.64
2.883
3.2
3.63
3.86
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
De
fle
ctio
n i
n m
m
Load in kN
Loas Vs Deflection
River Sand M-sand Control Beam
Study on Behavior of Sustainable Ferrocement Overlay Beam using M-Sand 158
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Biographies
S. Christi is a civil engineer graduate from University College of
Engineering, Ariyalur and obtain her post-graduate from AMS Engg College,
Namakkal. She is currently doing her doctoral degree at Annamalai
University, Chidambaram. She is presently working as Assistant professor in
St. Joseph College of engineering, Sriperumbudur. She is a Lifetime Member
in IAENG and IASE. She has been pursuing teaching for over three years.
She has been involved in research in the areas of concrete technology,
concrete structures and non-destructive testing.
A.Arunraj is a civil engineer graduate from K.S.R College of Engineering,
namakkal and obtain his post-graduate from AMS Engineering College,
Namakkal. He is currently working as an Assistant Professor, Department of
Civil Engineering, SRM Easwari Engg College, Ramapuram, Chennai. His
area of specialisation are concrete technology, concrete structures. He has 4
years of teaching experience. Published 02 International papers in scopus
indexed journal, 05 paper presented in national Conferences, and 01 paper
presented in International Conferences.
Study on Behavior of Sustainable Ferrocement Overlay Beam using M-Sand 160
Dr. Venkatesan.V was born in Irur Village on 03 June 1982 in Perambalur
District, Tamilnadu, India. He holds a Doctoral Degree in Hydrology and
Water Resources by the Anna University and is presently working as
Assistant Professor in the Department of Civil Engineering at University
College of Engineering Ariyalur (A Constituent College of Anna University
Chennai) since 2009. He has more than twelve years of teaching and research
experience. His area of specialisation are Remote sensing and GIS in
hydrology and Water resources applications. The Current research interst are
soft computing techniques in various applications of Water resources,
Irrigation Water Allocation, Studies on Repair of Concrete Elements and
Fiber Reinforced Concrete, Water Quality, Environmental Chemistry etc.
R.Logaraja He is a civil engineering graduate from NPR college of
engineering dindigul and obtain his post graduate from PSR engineering
college, sivakasi. He is currently working as an assistant professor in sethu
institute of technology, Madurai. His area of specialization are structural
dynamics and Earthquake engineering, special concrete and concrete
structure. He has published 8 international and 2 national journal. He has
received students scientist award from Tamilnadu science city, chennai