RESEARCH PAPER

International Journal of Recent Trends in Engineering, Vol. 1, No. 6, May 2009

Experimental and Analytical Model of Ferrocement Slabs

Assistant Lecturer, Civil Engineering Department, Faculty of Engineering, Menoufia University, Egypt Assistant Professor, Civil Engineering Department, Faculty of Engineering, Menoufia University, Egypt 3 Visiting Associate Professor, Civil and Environmental Engineering Department, Texas Tech University, USA Mostafa.el-shami@ttu.edu
2

Boshra Aboul-Anen1, Ahmed El-Shafey2, and Mostafa El-Shami3

Abstract-This paper addresses the composite action between the ferrocement slabs and steel sheeting. This is an important issue that could impact the performance and strength of space trusses. The current paper presents the experimental models of ferrocement slabs with and without steel sheeting and their numerical models using the finite element method. Finite element models were developed to simulate the behavior of the slab through nonlinear response and up to failure, using the ANSYS Package. Additionally, the comparison between the theoretical and experimental models is presented and discussed. Index Terms- space trusses, ferrocement, finite element

I. INTRODUCTION
Space structures are a leaf taken from Nature. Natural forms possess exceptional rigidity and use minimum materials to a maximum structural advantage. Historically Ref. [1], the earliest space structures built were the domes pioneered by the German Engineers Schwedler and Zimmermann in the nineteenth century. Zimmermann achieved a span of 118.44 m for an exhibition structure built at Lyons as early as 1894. In 1937, Mengeringhause realized that the promotion of space structures on a large scale would only be possible if the system lent itself to factory production and field assembly. To achieve these two objectives, it was necessary to reduce variety and develop a means of easy assembly. In 1942, Mengeringhause successfully commercialized space structures. His universal MERO node connector can accepts as many as 18 members at different angles in tapped holes over its surface. Two major approaches have been adopted for analyzing the collapse of the space structures; one deals with chord members in tension and the other deals with a brittle type of failure caused by buckling of cord members in compression. The buckling of cord members is the main problem facing space structures and has been a result, the subject of numerous experiments ([2], [3], [4] and [5]). It has been found that the compressive failure of a space structure is principally governed by the postbuckling load deflection characteristics of the struts. Several researchers ([6], [7], [3], [1] and [9]) have studied the over-strengthening of the compression members that can be adapted to prevent the brittle collapse of a space structure. One of the major suggestions is to use the composite action of concrete

slabs at the top. This reduces the buckling problems of the compression cord members and increases their load cap-cities. In general, the composite action has been found to improve joint stability and truss reliability; thus leading to significant enhancements to truss stiffness, strength and ductility. This approach also leads to improvements in truss response to member loss and uneven support settlements. The only disadvantage of using concrete slabs is the weight, which controls chord members span. In order to come over this problem, the authors suggest using light concrete slabs (ferrocement). This technique has been used since 1884 in the construction of row boats, plant pots, seats, housing, and other items. This material is commonly constructed of hydraulic cement mortar reinforced with closely spaced layers of continuous and relatively small size wire mesh Ref. [10]. The mesh may be made of metallic or other suitable materials. steel wire mesh may be wire mesh with closely spaced wires which is the most commonly used in the ferrocement, expanded metal, woven or welded wire fabric according to Ref. [11]. This material also used in repairing the reinforcement element; beams or slabs or walls Ref. [12]. Several recent studies ([13], [14], [15] and [16]) have indicated that ferrocement (with wiring meshes) is lightweight comparing to the reinforcement concrete. The main purpose of this research, then, was to investigate the possibility of using a top ferrocement slab to improve the behavior of space trusses. To construct space trusses with top ferrocement slab, decking plates (normally made of steel) should be used to support the wet concrete. The sheets will act with the ferrocement slabs as composite sections. This action will affect the total nonlinear behavior of space trusses. In this research, the authors focused on the composite action of the ferrocement slabs and steel sheets. In the following pages, experimental models of ferrocement slab with and without steel sheeting and their numerical models using the finite element method will be presented. Finite element models are developed to simulate the behavior of the slab through nonlinear response and up to failure, using the ANSYS package [17]. II. MODELS AND METHODS A. Experimental Model Ferrocement slabs both without steel sheeting (FS1) and

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International Journal of Recent Trends in Engineering, Vol. 1, No. 6, May 2009

with (FS2) were studied. The slabs dimensions were 0.8 x 0.8 m and 0.025 m thickness. The two slabs contain two wire meshes as shown in Figure 1. From the ferrocement definition, Ref. [13], mortar matrix and steel wire mesh are the main constituent materials of ferrocement. Mortar matrix is a homogeneous mix composed primarily of ordinary Portland cement, fine aggregate (sand) and water Ref. [13]. The sieve analysis was done on the sand used for the mortar mix and satisfied the Egyptian Standard Specifications (E.S.S.) requirements Ref. [18]. The chemical and physical properties of the cement were analyzed according to E.S.S. Ref. [18] for concrete works Fresh drinking water, free from impurities, was used for mixing and curing of the test specimens.

Figure 2. Shear Connectors C. Testing of Ferrocement Slabs Two wooden forms with dimensions of 0.8 x 0.8 m and thicknesses of 0.025 and 0.026 m were used for slab casting. These forms were constructed with specific precautions to facilitate the removal of the slabs after hardening. In both slabs FS1 and FS2 the following steps for casting and curing were followed: 1- Put a layer of hardening mortar with thickness of 4.0 mm in the wooden form, 2- Install the 1st wire mesh, 3- Cast a small pieces of the hardening mortar to support the 2nd layer of wire mesh, 4- Install the 2nd wire mesh, 5- Apply the hardening mortar intermittently as seen in Figure 3. 6- Remove the specimens from the wooden forms within 24 hours after casting. 7- Store the specimens in the laboratory atmosphere and covering it with wet cloth using water sprinkled twice a day for curing. 8- Test the specimens after 28 days. It should be noted that in FS2, the steel sheet was installed first before step # 1. The faces of each specimen were painted in white to facilitate crack detection before the testing. The specimen was placed in the testing position on frame as shown in Figure 5. The load is applied from a celebrated hydraulic Jake at the center line of the tested slab. The load was applied using the steel frame shown in Figure 4.

a. Longitudinal section in the first ferrocement Slab

(FS1)

b. Longitudinal section in the second ferrocement slab (FS2)

Figure 1. Specimens Details According to Ref. [13], the sand/cement ratio and water/cement ratio should be token 2 and 0.4; respectively to achieve the maximum compressive strength of the mortar mix. The woven wire mesh type with 1.42 mm diameter and 15x15 mm grid size was used. The used steel sheeting with thickness of 1 mm was cut into the required dimensions (0.8 X 0.8 m). Then small pieces (0.02 x 0.02 m) were cut, deformed and welded in the sheet as shown in Figure 2. These pieces were used as shear connector studs to assure the composite action between the ferocement slabs and the steel sheets. B. Properties of Used Materials Compression and tensile tests were carried out for the hardened mortar according to E.S.S. Ref. [18]. From the test results, the authors figured out that the compressive stress was equal to 19700 kN/m2 and 33300 kN/m2 at 7 and 28 days; respectively. For tensile strength, it was 2000 kN/m2. In order to determine the stress-strain curve and the modulus of elasticity of the mortar, four cylinders specimens were tested under compression. The strain was measured by means of an extensometer and demec points. The slope of the initial stage of the stress-strain is the modulus of elasticity which was calculated to be 3.0 E+7 kN/m2. The modulus of elasticity of the used steel meshes and yield strength were 13.0 E+8 kN /m2 and 4.0 E+5 kN/m2; respectively. For the steel sheets, the modulus of elasticity and yield strength were 2.1 E+8 kN /m2 and 2.4 E+5 kN/m2; respectively.

III. FINITE ELEMENT MODEL

A finite element package Ref. [17] was used to simulate the behavior of ferrocement slabs. Mainly two types of elements were used; solid 65, and solid 45. The properties of each element are as follows:A. Solid 65 This element is considered as one of the solid isoparametric elements which are formulated by direct extension of procedure used for plane elements Ref. [19]. It is defined by eight nodes as shown in Figure 5. Each node has three degrees of freedom, translations in x, y, and z; respectively. This element has one solid material and up to t hree rebar materials in the three directions

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International Journal of Recent Trends in Engineering, Vol. 1, No. 6, May 2009

Figure 5. Eight-node solid isoparametric element (solid 65) B. Solid 45 The element is similar to the solid 65 in its isoparametric properties. This element has a capability to handle plasticity, creep, swelling, stress stiffening, large deflection and large strain capabilities. In this study this element was used to simulate the steel sheeting in FS2. C. Modeling To model FS1, a block with dimensions of 0.8 x 0.8 x 0.025 m was built using solid 65 element type. The properties of its materials (mortar and wires) were defined using the experimental results mentioned before. Longitudinal and transverse reinforcement of used wires were applied using rebar in x-y plan. The steel wires in x and y directions are defined as two materials with same properties as mentioned before. The reinforcement in y direction is represented by rebar (1) with angles and equal to 90 and in x direction by rebar (2) with and equal to Zero (see Figure 5). For FS2, the model was the same as FS1 with exception of one addition. In FS1 one more block with dimensions of 0.8 x 0.8 x 0.001 m was built under that one used in FS1. This block was simulated the steel sheeting with properties mentioned above using solid 45 element type. It should be noted that the elements of each are oriented in the same way that they shear the same node at the interface between the two blocks. IV. RESULTS Both slabs FS1 and FS2 were tested utill failure. The failure load was measured for both slabs as 7.18 kN, and 31.42 kN; respectively. The crack pattern in FS1 is shown in Figure 6. In FS2, as load was applied a crack occurred between the steel sheet and the slab. This is contact failure happened around load of 10 kN (see Figure 7). The comparison between the two slabs for applied load and center deflection is given in Figure 8. Figure 9 compares the theoretical and experimental load-central deflection relationships for FS1. This figure illustrates that an excellent matching between both theoretical and experimental models occurred. The ultimate load predicted by the theoretical model was higher than the experimental one with only 7.89%.his might due to the

Figure 3. Slab casting

Figure 4. Slab testing and loading system This element is perfect to simulate reinforcement concrete slabs where the solid material is used to model the concrete or mortar (as in this study) and the rebar material to mode the reinforcement behavior. Reinforcement is specified by its material, volume ratio and orientation angles. The volume ratio is defined as the rebar volume divided by the total element volume. The orientation is defined by two angles in degrees ( and ) from the element coordinate system (see Figure 5). This element has cracking and crushing capabilities. The most important aspect of this element is the treatment of nonlinear material properties. The concrete or mortar is capable of cracking (in the three orthogonal directions), crushing, plastic deformation, and creep. The rebar (reinforcement) is capable of tension and compression, but not shear. The rebar is also capable of plastic deformation and creep Ref. [17]. In this study, this element was used to simulate the ferrocement slabs as in FS1, and FS2.

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assumption of perfect contact between mortar and reinforcements in the theoretical model.
8 7 6

Load (kN)

5 4 3 2 1 0 0 2 4 6 8 10 12 14

Theortical Experimental

Deflection (mm)

Figure 6. Crack pattern of FS1

Figure 9. Load verses deflection for FS1 (experimental and theoretical)

40 35 30

Load(kN)

25 20 15 10 5 0 0 5 10 15 20 25 30 35

Deflection (mm)

Figure 7. Contact failure in FS2 The comparison between theoretical and experimental load-central deflection relationship curves of FS2 is shown in Figure 10. This curve indicates a great matching between the two solutions up to 10.0 kN at which failure of bond between slab and steel sheeting occurred (see Figure 7). After 10.0 kN, the experimental and theoretical results continue to mismatch until failure load (Figure 10).
40 35 30

Figure 10. Load verses deflection for FS2 (experimental and theoretical) V. CONCLUSIONS The results of both experimental and analytical investigations to examine the composite action between the ferrocement slabs and steel sheeting are reported and discussed. This was done as an initial step towards using the ferrocement slabs to improve the behavior of compression member in spaced trusses. Manly two types of ferrocements slabs with and without steel sheeting were tested. The finite element technique was used to model the behavior of these slabs. ANSYS [17] was used to model all test specimens. The ANSYS model accommodates material non-linearities, cracking and crushing of concrete (or mortar) and yielding of the steel sheeting and wiring meshes. The analytical results compared well with the experimental for the ferrocement slabs without steel sheeting. For those specimens with steel sheeting, the comparison was good until the failure of the bond between the slabs and the steel sheeting. Further experimentation is required to better understand the role ferrocement slabs might play. It is believed that the future experiments will need to include addition steps and precautions to ensure better, even total, contact between ferrocement slabs and the steel sheeting.

Total Load (KN)

25 20 15 10 5 0 0 2 4 6 8 10 12 14

FS1 FS2

Deflection (mm)

Figure.8.Theoretical load-deflection curve

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REFERENCES
[1] A. I. El-Sheikh, Sensitivity of space trusses to member geometric imperfections, International Journal of Space Structures, vol. 2, pp. 89-98, 1995. [2] L.C. Schmidt, Load transfer for shear and torsion in platelike space trusses, Civil Engineering Transaction of the Institution of Engineers, pp. 1-7, Australia, 1981. [3] A.I. El-Sheikh, and R.E. McConnel, Experimental study of composite space trusses, Journal of Structural Engineering, ASCE, vol. 3, pp. 747-766, 1993. [4] R. Lecy, S. A. Hanaor, and N. Rizzuto, Experimental investigation of prestressing in doubly-layer grids, International Journal of Space Structures, vol. 1, pp. 2126, 1994. [5] A. I. El-Sheikh, and H. El-Bakry Experimental study of behavior of new space truss system, Journal of Structural Engineering, ASCE, vol. 8, pp. 845-853, 1996. [6] T. Bungey, Analysis of Space Truss Sensitivity to Member Loss and the Effects of Composite Action, M.S. Thesis, University of Dundee, UK, 1992. [7] M. Ashraf, M. A. Javied, and Z. Ali, Composite doublelayer bridge grids, Fourth International Conference on Space Structures, University of Surrey, Guildford, UK, pp. 1518-1525, 1993. [8] W. M. Sebastian, The Performance of A Composite Space Truss Bridge with Glass Reinforced Plastic Panels, Ph.D. Thesis, University of Cambridge, England, 1996. [9] A. I. El-Sheikh, Design of web members in space trusses, International Journal of Space Structures, vol. 1, pp. 25-34, 1999. [10] ACI, State-of-the-art report on ferrocement, 1980. [11] M. N. Soliman, Fleasibility of Using Fibrous Ferrocement Concrete in Strengthening and Repairing of Structural Elements, Ph.D. Thesis, Minufiya University, Egypt, 2006. [12] E. H. Fahmy, Y. B. Shaheen, and Y. S. Korany, "Use of ferrocement laminates for repairing reinforced concrete clabs," Journal of Ferrocement, vol. 3, pp. 219-232, 1997. [13] L. S. Blake, Civil Engineer's Reference Book, ButterworthHeinemann, Reed Educational and Professional Publishing Ltd, Oxford, 2001. [14] M. M. Hoque, 3D Nonlinear Mixed Finite-Element Analysis of RC Beams and Plates with and without FRP Reinforcement, M.S. Thesis, University of Manitoba, Canada, 2006. [15] D. Kachlakev, Finite Element Modeling of Reinforced Concrete Structures Strengthened with FRP Laminates, Ph.D. thesis, California Polytechnic State University, USA, 2001. [16] A. A. Nasser, Behavior and Strength of Ferrocement Composite Elements under Different Cases of Loading, Ph.D. Thesis, Minufiya University, Egypt, 2004. [17] ANSYS, Program Help and Manual, 1999. [18] Egyptian Standard Specifications, 2007. [19] R. Cook, D. S. Malkus, M. E. Plesha, Concepts and Applications of Finite Elements Analysis, 4th ed., John Wiley & Sons, Inc., 2001.

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