Flexural Performance of Ferrocement Laminates Containing Silicafume and Fly Ash Reinforced With Chicken Mesh

INTERNATIONAL Engineering and Technology (IJCIET), ISSN 0976 6308 (Print), International Journal of Civil JOURNAL OF CIVIL ENGINEERING
G AND ISSN 0976 6316(Online) Volume 3, Issue 2, July- December (2012), IAEME TECHNOLOGY (IJCIET)
ISSN 0976 6308 (Print) ISSN 0976 6316(Online) Volume 3, Issue 2, July- December (2012), pp. 130-143 IAEME: www.iaeme.com/ijciet.html Journal Impact Factor (2012): 3.1861 (Calculated by GISI) www.jifactor.com
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FLEXURAL PERFORMANCE OF FERROCEMENT LAMINATES CONTAINING SILICAFUME AND FLY ASH REINFORCED WITH CHICKEN MESH
K. SASIEKALAA Professor, Department of Civil Engineering, M.A.M College of Engineering, Trichy- 621 105, Tamilnadu, India. Email: sasimam.68@gmail.com R. MALATHY Professor & Dean (R&D), Department of Civil Engineering, Sona College of Technology, Salem- 636005,Tamilnadu,India. Email:dr.malathyramesh2009@gmail.com
ABSTRACT Ferro cement is a versatile construction material having unique properties of strength and serviceability that promote low cost technology in both urban and rural applications. The positive effects exerted by silica fume and fly ash on properties of Portland cement mortar have been emphasized. Flexure tests were conducted on ferrocement specimens replacing cement by silicafume(SF)and fly ash(FA) with superplasticizer.In the present study, slab specimens of size 500mm x150mm x 25mm with the following variables were investigated. i) chicken mesh reinforcement with volume fraction 0.943%,1.880%,2.823% and 3.770%.ii) Replacing cement by 5SF10FA(5%SF&10%FA), 5SF15FA, 5SF20FA, 5SF25FA and 5SF30FA.From the flexure study parameters such as first crack load, ultimate load, maximum deflection, and crack pattern were observed. From the experimental results it was found that the cement is replaced with the combination of 5% silica fume, 20% fly ash and 0.6%super plasticizer reinforced with volume fraction 2.823% and 3.770% leads to significantly improved flexural behaviour in terms of strength, toughness increased shear resistance and cracking. It can be effectively used for rehabilitation of reinforced concrete structures particularly with ferrocement composites. Key words: Ferrocement, silica fume, flyash, Galvanised chicken mesh, mortar matrix, flexural behaviour.
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International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print), ISSN 0976 6316(Online) Volume 3, Issue 2, July- December (2012), IAEME
1. INTRODUCTION In many countries around the world, silica fume and fly ash are used for producing active pozzolanic admixtures. These pozzolanic admixtures are used for reducing the Portland cement content in mortar and concrete production(T Cook DJ et al., 1985). The combination of silica fume and fly ash in a ternary cement system (i.e. Portland cement being the third component) should result in a number of synergistic effects, some of which are obvious as follows (Thomas M.D.A,1999). o o o o o Silica fume compensates for low early strength of concrete with low fly ash. Fly ash increases long term strength development of silica fume concrete. Fly ash offsets the increased water demand of silica fume. Very high resistance to chloride ion penetration can be obtained with ternary blends. The relative low cost of fly ash offsets the increased cost of silica fume.
Ferciment or Ferro-cemento or Ferrocement is the first invention of the reinforced concrete (ACI 549R-97; Naaman2000).Ferro cement is thin cement based on composite material. It has very wide applications due to its unique characteristics/mechanical properties, such as: environment friendly, sound technology; excellent tensile strength, improved toughness, water tightness, lightness, fire resistance, resistance to cracking and cost, time and material effective construction technology (Paul B.K and Pama.R.P. 1978).Compared to the reinforced concrete, ferrocement has homogeneous-orthotropic properties in two directions.It exhibits high tensile strength, high modulus of rupture and superior cracking performance. In addition, because of the high specific surfaces of ferrocement meshes, larger bond forces develop with the matrix resulting in smaller crack spacing and width (Naaman AE. 2000).In Ferro cement crack width at working load remains very small compared to that of the reinforced concrete, thereby leading to good impermeability, stiffness,and durability.(Onet.T,et al., 1992).The size of the mesh openings should be within 6-25mm (FMC 2001). Chloride induced corrosion of steel can be effectively improved by the use of the mineral admixtures in concrete such as fly ash, blast furnace slag and silica fume (Babu KG et al., 1993).The mineral admixtures such as fly ash, blast furnace slag and silica fume help the formation of finer and discontinuous pore structures as a consequence of pozzolanic reaction. The successful application of the ferrocement boats and roofing element is an indication that ferrocement is relatively resistant to the ingress of water (Akkan MS, et al., 1992). It is apparent that the ternary cementitious blends of Portland cement, silica fume and fly ash offer significant advantages over binary blends and even greater enhancements over ordinary Portland cement. In some cases, price differences between the individual components may allow the ternary blend to compete with with the ordinary Portland cement on the basis of material costs (Hariharan A.R et al.,2011). The availability of materials in most developing countries, and skilled labour required and for both prefabrication and self help construction could make ferrocement become one of the most inexpensive and attractive techniques to strengthen and rehabilitate the existing and damaged concrete structures (Jagannathan A. et al, 2006).
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Limited data exist in the literature on the flexural behaviour of ferrocement with modified cement matrix.The significant contributions of our paper to the ferrocement work are as follows. i)To explore the effects of adding silicafume and flyash with super plasticizer to ferrocement laminates. ii) Tests were conducted to study the flexural characteristics of the ferrocement laminates of low water binder ratio with the silica fume and fly ash in various proportions in the presence of a super plasticizer.iii)Ferrocement works demand cement mortars of good workability and high strength. It has to be done by including the optimum dosages of SF, FA and super plasticizer. iv)Furthermore, this paper speaks of the ferrocement panels reinforced with chicken mesh of volume fraction 0.943%,1.880%,2.823% and 3.770%. and their flexural performance was compared with that of the referred ferrocement panel. It considers the minimization of the manufacturing cost. 2. EXPERIMENTAL PROGRAM 2.1 Materials All the materials used during this experimental program comply with the standard specifications. 2.1.1 Cement The physical and chemical properties of the used Ordinary Portland cement (OPC) are tabulated in Table 1 and Table 2 respectively. 2.1.2 Fly ash High calcium fly ash (ASTM classC) from NLC limited, Neyveli, India was used in this investigation. The physical and chemical compositions of the fly ash are shown in Table1 and Table 2 respectively. 2.1.3 Silica fume Uncompacted silica fume from Elkern, India was incorporated in this study. The physical properties and chemical compositions of the silica fume are shown in Table 1 and Table 2 respectively. Table 1: Physical properties of cementitious materials Description of test ASTM TypeI Portland cement Specific gravity Fineness Initial setting time Final setting time Specific surfacem2/g Bulk density kg/m
3
Fly ash ASTM Class C 2.04 -
Silica Fume
3.15 94.1 150 min 265 min 329 -
2.02 85 19 602
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Table 2: Chemical composition of cementitious materials Description of test ASTM TypeI Portland cement SiO2 Al2O3 Fe2O3 CaO MgO SO3 Na2O3 K2O LOI 20.32 4.94 3.55 62.58 1.18 3.46 0.19 0.86 1.28 Fly ash ASTM Class C 60.09 18.63 1.10 1.54 0.31 0.05 2.41 85.72 0.06 0.45 1.96 Silica Fume
2.1.4 Fine aggregate Natural river sand with fraction passing through 2.36mm sieve was used as per recommendation of ACI 549 IR 93.The specific gravity of fine aggregate was 2.658. 2.1.5 Super plasticizer The super plasticizer of trade name Fosroc Conplast SP430 conforming to IS 9103-1999 and ASTMC-494 was used as the chemical admixture during this study. It is available as a medium brown coloured aqueous solution and its specific gravity is 1.18. 2.1.6 Water Good quality drinking water was used for the preparation and curing of specimen. 2.1.7 Meshes The galvanized chicken mesh was used because it is cheap, user friendly and readily available in the open market. Salient physical properties of the mesh are evaluated and given in table 3.
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Table 3: Physical properties of the chicken mesh used in ferrocement Properties/Description Raw material Mesh shape Width(m) Mesh opening(mm) Thickness at joint(mm) Diameter of wire(mm) Unit weight(Kg/m ) Density(Kg/m3 )
2
Chicken mesh steel Hexagonal 1 15 X 10 1.5 0.5 1.85 7850
2.2 Preparation of ferrocement test specimens 2.2.1 Mortar for ferrocement Mix proportion for ferrocement was selected from the results of compressive strength. (sasiekalaa et al.,2012).Table 4 shows the details of the mix proportion of mortar for ferrocement slab. Table 4: Mix proportion of mortar for ferrocement slab Binder: sand Silica fume Fly ash Water binder ratio Super plasticizer Design compressive strength Mesh 1:2 5% of total binder by weight 10%,15%,20%,25% and 30% of total binder by weight 0.35 0.6% of total binder by weight About 60Mpa 1 layer,2 layers,3 layers and 4 layers
2.2.2 Preparation of ferrocement slab A specimen of ferrocement slabs of size 500x150x25mm with 1:2 mix,0.35 water binder ratio, partial replacement of cement with 5% silica fume and fly ash content varied from
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10%,15%,20%,25% and 30% by weight of cement were prepared. The dosage of super plasticizer used is 0.6% by weight of total binder. Thus a total of 72 specimens of the above size were cast by placing chicken mesh with volume fraction 0.943%, 1.880%, 2.823% and 3.770%. 2.3 Flexural testing of Ferro cement slabs 2.3.1 Instrumentation and loading procedure All specimens are subjected to flexure under two point loading. The test set up is shown in Fig.1.The slabs were simply supported with an effective span of 400mmc/c. Two point loads were applied transversely at one third distance from the support. Dial gauge of sensitivity 0.01mm was used to measure the deflection of the slabs at mid span. The behaviour of the slabs was keenly observed from the beginning till collapse. The observations were made for: a) Deflection at the midpoint for each 0.5kN increment of loading b) Load at first crack c) Ultimate load d) Crack formation and its spacing e) Mode of failure of all specimens. The propagation of the initial cracks owing to the increase of load was also recorded. The loading continued till the verge of collapse.
Fig.1 Test set up 3. Flexural behavior of the ferrocement panels The results of the flexural test on ferrocement panels with and without mortar modification for the chicken mesh are given in table 5. 4. RESULTS AND DISCUSSIONS 4.1 Load Vs Deflection Effect of number of layers Figure 2 to figure 7 shows the load deflection characteristics of the ferrocement panels with 5SF10FA, 5SF15FA, 5SF20FA, 5SF25FA and 5SF30FA for chicken mesh of volume fraction 0.943%,1.880%,2.823% and 3.770%. It is seen that the ferrocement laminates exhibit linear elastic behavior up to the maximum load, irrespective of number of layers of mesh used. After reaching the ultimate load, the deflection of the ferrocement panels reinforced with the mesh tend to decrease gradually. The panels reinforced with volume fraction of 0.943% fail suddenly
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after reaching the maximum load which is essentially due to the deficient bond of the chicken mesh with the matrix. 4.2 First Crack Load and Failure Load From the table 5 first crack load and failure load were found to be the maximum for 5SF20FA. First crack load and failure load increase with the increase in the volume fraction of mesh.The maximum value of the first crack load was found to be 1.9kN and the maximum failure load was found to be 4kN.Variation of the first crack load and the failure load with % replacement is shown in figure 8 & figure 9. 4.3 Mode of failure Flexural failure was observed for all specimens. Most of the cracks were generated near the centre and on increase in loads multiple cracks were generated at different locations. Average spacing of cracks was found to be almost equal at higher loads and failure occurred at loading points. Table 5 :Details of test results of ferrocement laminates Mortar mix Volume fraction(%) 0.943 Control specimen 1.880 2.823 3.770 0.943 5SF10FA 1.880 2.823 3.770 0.943 1.880 5SF15FA 2.823 3.770 0.943 1.880 5SF20FA 2.823 3.770 First crack load (kN) 1.1 1.3 1.5 1.8 1.1 1.2 1.4 1.5 1.1 1.2 1.3 1.5 1.1 1.3 1.7 1.9 Ultimate load (kN) 1.1 1.3 2.1 3.7 1.4 1.3 2.4 3.8 1.5 1.4 2.3 3.7 1.6 1.5 2.4 4.0 Maximum deflection(mm) 6 8 11 20 7 8.5 13 21 7 6.5 12 18 9 8 11 19
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0.943 1.880 5SF25FA 2.823 3.770 0.943 1.880 5SF30FA 2.823 3.770
1.0 1.1 1.4 1.6 0.9 1.0 1.3 1.6
1.2 1.2 1.9 2.9 1.1 1.0 1.8 2.8
8 10 18 24 6 10 16 25
4.4 Maximum Deflection In the case of one layer and two layer of reinforcement for various mortar modifications, the maximum deflection is found to be nearly the same. The maximum deflection is within the allowable limit as per the codal provisions of ACI 549 IR 93 4.5 Effect of mortar modification The effect of addition of fly ash and silica fume on the flexural load carrying capacity is found to be insignificant upto two layers of mesh in the ferrocement panel. It is very effective in preventing the spalling of the mortar cover at ultimate load. It leads to significantly improved flexural behavior in terms of strength, toughness, increased shear resistance and cracking. Hence ferrocement panel with 5% silica fume and 20% fly ash reinforced with chicken mesh of volume fraction 2.823% and 3.77% is the optimum value. 5. Toughness Index: Toughness is a measure of the energy absorption capacity of a material and is used to characterize the materials ability to resist fracture. Energy absorption capacity of the matrix is increased by increasing the volume fraction of mesh which can be evaluated by determining the area under the load deflection curve. Variation of toughness index with %replacement of all ferrocement panels is shown in figure 10. Hence ferrocement panel with 5% silica fume and 20% fly ash reinforced with chicken mesh of volume fraction 2.823% and 3.77% had the higher energy absorption capacity.
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LOAD VS DEFLECTION
4.5 4 3.5
Load in kN
3 2.5 2 1.5 1 0.5 0 0 5 10 15 20 25
layer 1 layer 2 layer 3 layer4
Deflection in mm
Figure 2 :Load deflection plot for specimen without mortar modification
LOAD VS DEFLECTION
4.5 4 3.5
Load in kN
3 2.5 2 1.5 1 0.5 0 0 5 10 15

20 25
Deflection in mm
Figure 3:Load deflection plot for specimen with 5% silicafume and 10% fly ash
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LOAD VS DEFLECTION
4.5 4 3.5 3
Load in kN
2.5 2 1 0.5 0 0 5 10 15 20 1.5
layer 1 layer 2 layer 3 layer4 Deflection in mm
LOAD VS DEFLECTION
4.5 4 3.5 3
Load in kN
2.5 2 1 1.5 0.5 0 0 5 10 15 20
Deflection in mm
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LOAD VS DEFLECTION
4.5 4 3.5 3
Load in kN
2.5 2 1 0 0 5 10 15 20 25 1.5 0.5
layer 1 layer 2 layer 3 layer4 Deflection in mm
LOAD VS DEFLECTION
4.5 4 3.5
Load in kN
3 2 1
2.5 1.5 0.5 0 0 5 10 15 20 25
Deflection in mm
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First crack load vs % replacement 2.5 First Crack Load in kN 2 1.5 1 0.5 0 0 5SF10FA 5SF15FA 5SF20FA 5SF25FA 5SF30FA % Replacement
1 Layer 2 Layer 3 Layer 4 Layer
Figure 8:First crack load versus % replacement
FAILURE LOAD VERSUS % REPLACEMENT 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 0
Failure Load in kN
1 Layer 2 Layer 3 Layer 4 Layer
5SF10FA 5SF15FA 5SF20FA 5SF25FA 5SF30FA % Replacement
Figure 9:Failure load versus % replacement
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1 LAYER 8 7 2 LAYER 3 LAYER 4 LAYER
Toughness Index
6 5 4 3 2 1 0 0 5SF10FA 5SF15FA 5SF20FA 5SF25FA 5SF30FA
% Replacement Figure 10:Toughness index versus % replacement

6. OPTIMUM RESULT Based on the load carrying capacity, deflection and crack width, the partial replacement of cement by 5SF20FA with volume fraction 2.823% and 3.77% is considered as optimum. The above panels exhibit cracks that are possible to be easily identified by the naked eyes, with the result that there is slow propagation.i.e progressive cracking behavior. However, brittle failure is exhibited. The above behavior is clearly due to the contribution of silica fume and fly ash which has helped to bridge the cracks that have developed and prevent breaking of specimens. 7. CONCLUSION Based on the experimental study conducted and the results presented herein, following conclusions can be drawn. Ferrocement panels with chicken mesh exhibit linear elastic behavior.(i.e. with respect to load vs deflection),up to the maximum load irrespective of the volume fraction of mesh reinforcement used. It has improved the workability of the mortar. An addition of super plasticizer improves the matrix penetration of the mesh system. There is an increase in the load carrying capacity of the ferrocement panels with the increase in the volume fraction of the mesh reinforcement. Thus based on the load carrying capacity, deflection and crack width, the partial replacement of cement by 5SF20FA with volume fraction 2.823% and 3.770% is considered as optimum. The above panels exhibit cracks that can be easily identified with the naked eye, with the result that there is slow propagation.i.e progressive cracking behaviour. However brittle
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failure is exhibited. But the cracked specimen does not separate into various pieces resulting in the reduction of the crack widths. The above behavior is clearly due to the contribution of the silica fume and fly ash which has helped to bridge the developed cracks and prevent breaking of the specimens. From the experimental results it was found that the cement replacement by 5% silica fume, 20% fly ash and incorporation of 0.6% super plasticizer can successfully produce mixes of adequate early strength and increased long-term strength development coupled with excellent flow characteristics. It can be effectively used for the rehabilitation of the reinforced concrete structures particularly with the ferrocement composites.
8. REFERENCES 1. ACI Committee 549R (1997), State of the Art report on Ferrocement, Manual of concrete practice, ACI, Farmington Hills, Michigan ACI 549R-97. 2. Akkan MS, Mazlum F(1992), A comparative study of natural Pozzolanas used in blended cement production,Proc fourth international conference on fly ash, silica fume, Slang and Natural Pozzlanas in concrete, Istanbul, Turkey 1:471 94. 3. Babu KG, Rao GSN, Prakash PVS, (1993),Efficiency of pozzolanas in cement composites, concrete 2000, published by E & FNSPON497 509 4. Cook DJ (1985), Calcined clay, shale and other soils, Cement replacement materials concrete technology and design, 3:40 70 Survey university press. 5. Ferrocement Model code, January (2001),Reported by International Ferro cement Society (IFS) committee 10, Published by Asian Institute of Technology, International Ferro cement information centre, Bangkok, Thailand, 89. 6. George J,XuZ,Danie F,Watt P,Hudec (1995),Effectiveness of mineral admixtures in reducing ASK expansion, cement concrete Reseaech,6(25):1225-35. 7. Hariharan.A.R,Santhi.A.S,Mohan Ganesh.G(2011),Effect of ternary cementitious system on compressive strength and resistance to chloride ion penetration,International J civil and structural Engineering, (4) 8. Jagannathan A,Sundarajan T,(2006),Flexural characteristics of ferrocement panels reinforced with polymer mesh and polypropylene fibers.Proceedings of eigth International symposium and workshop on ferrocement and thin reinforced cement composites.0608,Bangkok. 9. Naaman, AE (2000), Ferro cement and laminated cementitious composites, Ann Arbor, Michigan, USA: Techno press. 10. Onet.T, Magureanu.C and Vescan.V (1992), Aspects concerning the behavior of Ferro cement in flexure, J ferrocement.22 :1-9 11. Paul B.K and Pama R.P,Ferrocement(1978) published by IFIC,IT,Bangkok,Thailand,149pp. 12. Ruiz A(1965),Strength contribution of a Pozzolona to concretes, proc J Amer concrete Inst 62:315- 24. 13. Sasiekalaa K,Malathy R(2012),Behaviour of mortar containing silica fume and fly ash,Journal of industrial pollution control,28:1-7. 14. M.D.A.Thomas,M.H.Shehata,S.G.Shashiprakash,D.S.Hopkins,K.Cail(1999),Use of ternary cementitious systems containing silica fume and fly ash in concrete,Cement and Concrete Research 29:1207-1214.
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Flexural Performance of Ferrocement Laminates Containing Silicafume and Fly Ash Reinforced With Chicken Mesh

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Flexural Performance of Ferrocement Laminates Containing Silicafume and Fly Ash Reinforced With Chicken Mesh

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INTERNATIONAL Engineering and Technology (IJCIET), ISSN 0976 6308 (Print), International Journal of Civil JOURNAL OF CIVIL ENGINEERING

Fly ash ASTM Class C 2.04 -

3.15 94.1 150 min 265 min 329 -

Chicken mesh steel Hexagonal 1 15 X 10 1.5 0.5 1.85 7850

1.0 1.1 1.4 1.6 0.9 1.0 1.3 1.6

1.2 1.2 1.9 2.9 1.1 1.0 1.8 2.8

3 2.5 2 1.5 1 0.5 0 0 5 10 15 20 25

layer 1 layer 2 layer 3 layer4

Figure 2 :Load deflection plot for specimen without mortar modification

3 2.5 2 1.5 1 0.5 0 0 5 10 15

layer 1 layer 2 layer 3 layer4

2.5 2 1 0.5 0 0 5 10 15 20 1.5

layer 1 layer 2 layer 3 layer4 Deflection in mm

2.5 2 1 1.5 0.5 0 0 5 10 15 20

layer 1 layer 2 layer 3 layer4

2.5 2 1 0 0 5 10 15 20 25 1.5 0.5

layer 1 layer 2 layer 3 layer4 Deflection in mm

2.5 1.5 0.5 0 0 5 10 15 20 25

layer 1 layer 2 layer 3 layer4

1 Layer 2 Layer 3 Layer 4 Layer

Figure 8:First crack load versus % replacement

FAILURE LOAD VERSUS % REPLACEMENT 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 0

1 Layer 2 Layer 3 Layer 4 Layer

5SF10FA 5SF15FA 5SF20FA 5SF25FA 5SF30FA % Replacement

Figure 9:Failure load versus % replacement

6 5 4 3 2 1 0 0 5SF10FA 5SF15FA 5SF20FA 5SF25FA 5SF30FA

% Replacement Figure 10:Toughness index versus % replacement

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