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Experimental and Analytical Model of Ferrocement Slabs

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 RESEARCH PAPER International Journal of Recent Trends in Engineering, Vol. 1, No. 6, May 2009
Experimental and Analytical Model of
Ferrocement Slabs
Boshra Aboul-Anen1, Ahmed El-Shafey2, and Mostafa El-Shami3
1
Assistant Lecturer, Civil Engineering Department, Faculty of Engineering, Menoufia University, Egypt
2
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
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 post-
buckling 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
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© 2009 ACADEMY PUBLISHER
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
member’s 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
 RESEARCH PAPER 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.
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.
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© 2009 ACADEMY PUBLISHER
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.
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
 RESEARCH PAPER International Journal of Recent Trends in Engineering, Vol. 1, No. 6, May 2009
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 (θ and φ)
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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© 2009 ACADEMY PUBLISHER
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 θ and φ
equal to 90ْ and in x direction by rebar (2) with θ and φ
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
 RESEARCH PAPER International Journal of Recent Trends in Engineering, Vol. 1, No. 6, May 2009

assumption of perfect contact between mortar and

reinforcements in the theoretical model.
8

Load (kN)
4

2
Theortical
1
Experimental
0
0 2 4 6 8 10 12 14
Deflection (mm)
Figure 9. Load verses deflection for FS1 (experimental
Figure 6. Crack pattern of FS1 and theoretical)

40

35

30

25
Load (kN)

20

15

10

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
Total Load (KN)
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

25
crushing of concrete (or mortar) and yielding of the steel
20 sheeting and wiring meshes. The analytical results
15 FS1 compared well with the experimental for the ferrocement
FS2 slabs without steel sheeting. For those specimens with
10
steel sheeting, the comparison was good until the failure
5 of the bond between the slabs and the steel sheeting.
0 Further experimentation is required to better understand
0 2 4 6 8 10 12 14 the role ferrocement slabs might play. It is believed that
Deflection (mm) the future experiments will need to include addition steps
Figure.8.Theoretical load-deflection curve and precautions to ensure better, even total, contact
between ferrocement slabs and the steel sheeting.

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

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