International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 7 (2018) pp.

284-291
© Research India Publications. http://www.ripublication.com

FLEXURAL BEHAVIOUR OF GEOPOLYMER BASED FERROCEMENT PANELS

Anusha
1
Research Scholar, School of Civil Engineering REVA University, Bangalore, Karnataka, India.
Ambily P. S2
2
Senior Scientist, Csir-structural engineering research centre Chennai India,
Bhagvan N. G3
3
SeniorPrincipal scientist Csir-structural engineering research centre Chennai India
Spoorthi S Hiremath4
4
Assistant Prof., School of Civil Engineering REVA University, Bangalore India

Abstract INTRODUCTION
Ferrocement is special form of reinforced cement concrete Portland cement is popularly used as the basic raw-material
(RCC) without coarse aggregate and reinforced with closely (as a primary binder) in concrete mixes, for all the
spaced multiple layers of mesh encapsulated in rich cement construction works. Reinforced cement concrete (RCC)
mortar. Ferrocement sections are relatively thin in structural elements of typical construction projects, consume
construction and requires comparatively less reinforcement. huge quantities of cement. Very high cement consumption for
They can be moulded into any shape and size, which may not RCC constructions not only shoots-up the economic costs of
be the case with conventional RCC elements. The the project, but also would hugely increase the ecological
construction dosen’t necessarily requires shuttering, pollution issues associated with cement production plants. In
formwork, etc. And are highly versatile material possessing a this context, engineering research projects were taken-up,
high degree of ductility, durability, strength, crack resistance across the globe, on technological development for alternative
that is greater than that of RCC structural elements. This type construction technologies (to replace popular RCC
of construction facilitates precast systems, as the ferrocement construction techniques), towards the objective of relatively
sections are not only thin, but also light weight enough for reducing the cement consumption. Prestressed structures,
ease of handling. Applications of ferrocement are numerous. precast technologies, ferrocement construction, etc., have
Since, ferrocement appears to be an economic alternative been emerged as viable engineering practices in this direction.
material, here in this research study, it is envisaged to utilise it
Ferrocement was considered as one of the construction
as primary precast roof panel elements of a proposed
technologies, by American Concrete Institute committee 549.
prefabrcicated roofing system.
Ferrocement elements are reinforced composites, those differ
Geopolymer, a novel binder, a type of inorganic polymer from normal conventional reinforced cement concrete (RCC)
synthesised from room temperature by using industrial waste elements. According to ACI committee, Ferrocement are the
or by-products as source materials to form a solid binder, is thin walled reinforced elements generally constructed of
also used as binder for complete replacement of Ordinary hydraulic cement mortar reinforced with closely spaced layers
Portland cement (OPC). The main objective of this research of continuous and relatively small sized diameter wire mesh.
work is to study the comparative flexural behaviour of precast When compared to conventional reinforced cement concrete
panels containing weld mesh and (chicken) wire mesh (RCC) elements, the ferrocement has structural advantages of,
reinforcement grill, packed / cast in both types of higher tensile strength / high modulus of rupture /
conventional OPC mortar/geopolymer mortar. The precast homogeneous properties / high resistance to punching shear
panels of cement mortar are conventionally designated as failure and impact loading/ lesser crack widths, etc.
‘FERROCEMENT PANELS’, whereas the precast panels of Ferrocement is used in many construction applications [13]
geopolymer mortar are innovatively termed as “GEO-
FERROCRETE PANELS”. The geo-ferrocrete panels were
air-cured under ambient temperature conditions and LITERATURE REVIEW
ferrocement panels were cured under water for 28 days. The
sizes of the precast roofing panels were fixed at 1000 mm According to N.P. Rajamane, the compressive strength of
geopolymeric mortar were higher in which the geopolymeric
long, 600 mm wide and 30 mm thick. Comparative flexural
materials was activated by sodium hydroxide and sodium
performance shows Ferrocement panels have good flexural
silicate solutions [1]. In Madeshwaran C. K’s research work
behavior compared with geo-ferrocrete panels.
explains about the compressive strength of GGBS and flyash
Keywords: Flyash, GGBS, Ferrocement, Roof slab, with varying percentage and varying the molarities of
Deflection, flexural test Alkaline solution and also specified that concentration of
NaoH increases strength and greater strength achieved with
100% replacement of GGBS [2]. Sreevidya. V research work

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explains about the curing of geopolymer mortar specimens it Table 1 Physical properties of OPC
explains that strength gain at ambient curing conditions gaved
less strength when compared with curing at higher Physical properties OPC Cement
temperature curing conditions [3]. Standard consistency of cement 30%
Specific gravity of cement 3.14
Hago.K. studied about the service behavior of Ferrocement
roof panels with incorporating different layers of chicken Initial setting time (Minutes) 55
mesh and rectangular mesh and also explains about the Final setting time (Minutes) 215
cracking and ultimate flexural behavior of Ferrocement
specimens [4][5]. Swapnil and Aathinavi, studied about
different shaped panels in Swapnil’s research work shows the FINE AGGREGATES
results related to Ferrocement segmental elements and studied Tests were also conducted to find the specific gravity of the
about the load behavior and load bearing capacity of the fine aggregates using pycnometer as per IS 2386-1963
elements [6]. In Aathinavis research studied about the folded (Part- 3).
panels and were subjected to different loading and cost
parameters were also studied for the Ferrocement elements Table.2 Properties of fine aggregate
[7]. Amruthas research paper studied about the through Specific gravity 2.5
shaped panels with different layers of mesh and varying Fineness modulus 3.1
percentage of SBR polymers and studied about load bearing
The river sand falls under Zone Ⅱaccording to IS 383-1970
capacity and crack width studies [9]. Suresh R research work
says that Ferrocement elements are flexible and strong due to Bulk density 1647kg/m3
the even distribution of reinforcement. And studied about the
flexural behavior of panels with partial replacement of flyash
and incorporating weld mesh and chicken mesh as PREPARATION OF ALKALINE SOLUTION
reinforcement; under flexural loading it showed that The alkaline solution is prepared 24 hours before the casting.
Ferrocement were good in bending and had good crack It is prepared by mixing sodium hydroxide in liquid /pellets
resistant [8]. In Suhail H experimental research work showed form in water and after the temperature come down the
that Ferrocement elements witn double layer of mesh gaved sodium silicate solution is added to the mix before 30 minutes
good flexural strength comparedwith single layer of mesh and of casting.
geopolymer mortar had good strength compared with
Ferrocement elements [10].. In Ranjith K and Murali G
explains about the ferrocemnt elements cast cement mortar GROUND GRANULATED BLAST FURNACE SLAG
and geopolymer mortar incorporating wire mesh and AND FLY ASH
hexagonal mesh with different layers showed good flexural
behaivour and higher stiffness and ductility under loading and The fly ash is fiery debris obtained from the warm power
also had higher energy absorbent when subjected to impact plant. It is a decent pozzolano and remains either dark or grey.
loading and flexure. [13] [14]. The fly ash used in the study was obtained from Ennore
thermal power plant, Tamilnadu. Ground granulated blast
furnace slag is a hydraulic binder obtained from the blast
MATERIALS USED furnaces of iron and steel plants. The physical properties of
flyash and GGBS are studied by weighing required quantity of
The cement used for casting all experimental specimens, is the flyash and GGBS and using Vicat apparatus mould. To
ultra tech brand of OPC 53- grade. Its properties were studied determine the normal consistency, initial and final setting time
according to IS:4031(part 2)-1988. Geopolymeric materials of geopolymer mix which includes 60% of GGBS and 40%
used for producing geo-ferrocerete panels are, flyash and Flyash is taken and alkaline solution made of sodium
Ground Granulated Blast Furnace Slag (GGBS). Flyash and hydroxide and sodium silicate is used to prepare the
GGBS were brought from Ennore power plant and steel plant, geopolymer paste. The normal consistency is started initially
respectively. The fine aggregate used was of standard size of by added 28% of solution by weight of binder and tested as
less than 4.75mm, and it is the locally available river sand. per the procedure specified by IS 4031-1988 (Part 4), until the
The distributed reinforcement consists of square weld mesh of needle penetrates to a depth of 33 to 35 mm from the top.
30mm*30mm opening and diameter of 2.5mm in both
longitudinal and transverse direction and chicken mesh of 36- Table 3 Physical properties of flyash and GGBS
gauge chicken mesh of 10mm opening were used. The
Physical properties Flyash and
preliminary studies are performed according to the IS code GGBS
recommendations.
Standard consistency of fly ash and GGBS 31.5%
Specific gravity of fly ash 1.966
PROPERTIES OF CEMENT MORTAR Specific gravity of GGBS 2.74
Initial setting time (Minutes) 40
The cement used to find the properties are Ultratech brand
cement of OPC 53 grade and the properties are studied Final setting time (Minutes) 150
according to specified IS codal provision.

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REINFORCEMENT PROVIDED Table 3.7 Constituents of geopolymer mortar

Square weld mesh:. The weld mesh was cut to a required Geopolymer binder Fine Alkaline
dimension of 1000mm*600mm. Single layer of weld mesh is aggregate solution
Fly ash GGBS
provided in the specimen panels. The mesh which can be
distributed evenly in both directioms. 140kg 210kg 1060kg 215kg
1 3 0.61
Chicken mesh: It is known as chicken mesh or hexagonal
mesh. It is generally used in the poultry forms. Due to its thin
dimension and strength properties it is being used as a EXPERIMENTAL INVESTIGATION
reinforcing material. It is provided in 2 layers above and
below the square weld mesh. Experimental investigation consists of study of flexural
behavior of test panels and study of deflection under constant
loading and also consists of strain behavior of the panels
under loading.

DETAILS OF TEST SPECIMENS

The cross sectional dimensions of the ferrocement and geo-
(a) (b) ferrocrete panels were adopted by standard principles. Total of
Fig 1 (a) Weld mesh (b) Weld mesh with 2 layers of 8 panels were cast which includes4 geo- ferrocrete panels and
chicken mesh 4 ferrocement panels. The overall dimension of the panels is
1000 mm length, 600 mm width and 30 mm thick. These
panels include single layer of weld mesh and double layer of
Table.4 Specification of hexagonal mesh chicken mesh, and the reinforcement is placed at the mid
span.
Sl.No Properties Values
1 Shape of opening Square
2 Length 1000 mm
3 Width 600 mm
4 Mesh opening 30 mm*30 mm
5 Thickness of joint 5 mm
6 Diameter of mesh 2.5 mm
7 Available form Rolls

Table.5 Specification of chicken mesh

Sl.No Properties Values
Fig 4.1 Details of test specimen Table 4.1 details of the
1 Shape of opening Hexagonal specimen
2 Length 1000 mm
3 Width 600 mm
CASTING AND CURING OF FERROCEMENT AND
6 Diameter of mesh 0.2 mm GEO-FERROCRETE PANEL
7 Available form Rolls
For Casting of test panels, the mortar was spread on steel
mould and a layer of mortar is spread through the mould and
MIX PROPORTIONS single layer of weld mesh and double layer of mesh prepared
is placed at the mid span of the mould after the placement of
The mix ratio of both cement mortar mix and geopolymer mesh the next layer of mortar is laid and surface is finished,
mortar mix used in the present study adopted is 1:3. same procedure is carried foe geo-ferrocrete panel and
Ferrocement panels. The panels were demoulded after 24
hours of casting and cured it with gunny bags for 28 days,
Table.6 For water cement ratio 0.45 whereas geo-ferrocrete panles cast with geopolymer mortar
Cement Fine aggregate Water were cured under room temperature. For casting the materilas
were weighed, dried and mixed in a concrete mixer, before
435kg 1310kg 200kg casting oil were applied on the surface of the mould and
1 3 0.45 mortar was laid in layers’ care was taken to ensure motar was
laid properly and compacted.

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surface of substrata to be smooth. Acitone clear splint is used

to remove the inert particles from the panels. Two strain
gauges were fixed, one at 1/3rd span and the other at 2/3rd
span, to measure the strain at particular points. They were
Fig.2 preparation of mould for casting EXPERIMENTAL marked using meter scale. Both instruments, the LVDT and
TEST SETUP strain gauges were connected to data acquisition system.
LVDT’s were used to measure axial deformation of maximum
50mm. The strain gauges were fixed for the measured gauge
The primary investigation of this experimental investigation is length of 60mm. CN- adhesive was used to paste the strain
to study the comparative flexural behaviour of ferrocement gauges. Both instruments, the LVDT and strain gauges were
with that of geo-ferrocrete panels; The panel specimens were given initial corrections and verified before the applying the
tested at the facture and fatigue laboratory of CSIR-SERC. load. Static load application was administered on the
Testing was done using multipurpose servo hydraulic universal specimen panels.
testing machine of 500KN capacity. The mode of control of the
machine is displacement control. The stroke length of UTM is
±75mm. The panels were placed over the specially fabricated
supporting system. All the specimens were tested by providing
simply supported condition. The load is applied as two point
placed concentrated loads, at one-third span and two-third
span. The slab is kept on the prepared test set-up which
includes a L- shaped beams on both the sides, as pedestals.
Above these pedestals, one side hinge support and other side Fig.4 Instrumental setup
roller support were provided for freely allowing moment and
to attain a good deflection.
EXPERIMENTAL OBSERVATION OF GEO- FERROCRETE
PANELS
The behaviour of panels under flexure was observed by using
LVDT and stain gauges. The initial loading was started from 0
and displacement rate of loading was 0.01mm/min. The
behaviour of panels was recorded until the ultimate cracking.

(a) (b) (c)

Fig .3 (a) Testing machine (b) Flexural test setup
(c) Test setup after placing slab

INSTRUMENTATION
The slab was instrumented with single linear variable (a) (b)
differential transducer (LVDT) to measure the deflection at Fig.5(a) Testing of geo-ferrocrete panel (b) Tested
the mid-point of span. First a sand-paper is used to prepare the specimen

Table 5.1 Experimental test results

Specimen Reinforcement Specimen Cracking load Ultimate load Remarks
designation ID
Load Deflection Load Deflection
(kN) (mm) (kN) (mm)

Geo- Single layer of weld Mesh FG-1 0.5 10.00 3.59 32.53 The Initial cracking at b0.5k N
ferrocement and double layer of chicken was observed due to the
mesh FG-2 2.68 16.80 6.31 47.28 improper cover in the FG-1
Panels (FG)
specimen
FG-3 2.01 22.44 6.25 28.52

FG-4 1.81 23.48 5.93 33.51

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(a) (b)

Fig.6 (a), (b), (c) and (d)-Load and deflection behaviour of

Geo-ferrocrete panels

(c) (d)
Fig.8 (a), (b), (c), (d)-Load and deflection behaviour of
ferrocement panels

Fig.7 Result of geo-ferrocrete panels

EXPERIMENTAL OBSERVATION OF FERROCEMENT

PANELS

Fig.9 Result of Ferrocement panels

STRAIN OF THE FERROCEMENT AND FERRO-

Fig.7 (a) Flexure test of ferrocement panel (b) Behaviour GEOPOLYMER PANELS WERE OBSERVED
of specimen Strain gauge readings from the testing are observed. The
strain gauges were used to record the strain pattern. The
average strains of the both the strain gauges were worked-out
Table.6 Experimental test results and listed in the following tables. The strain values of geo-
Slab Reinforcement specimens Cracking Ultimate load ferrocrete panels were more compared with Ferrocement
designation ID panels it shows that Ferrocement panels are good in
Load Deflection Load Deflection deformation compare to geo-ferrocrete panels
(kN) (mm) (kN) (mm)
Table.7 Strain values of Geo-ferrocrete panels
Ferroc Single layer of FC-1 4.0 22.88 6.274 26.152
ement (FC) weld mesh and Slab Reinforcement Specimen s Strain
double layer of FC-2 4.5 18.82 6.685 20.024
chicken mesh designation ID Load(kN) Strain
FC-3 5.09 21.05 5 9.849 26.549
Geo- Single layer of FG-1 3.28 12657
FC-4 6.30 15.90 8.156 22.856 Ferrocrete weld mesh and FG-2 6.294 7624
panels (FG) double layer of
chicken mesh FG-3 6.21 5810
FG-4 5.79 5798

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Fig.12 compressive strength test result

SPLIT TENSILE STRENGTH TEST

The split tensile test is believed to give more uniform results
compared with other tension test. The split tensile test is done
Fig.10 (a), (b), (c), (d) strain plot for geo-ferrocrete panels according to IS:5816-1999 codal recommendations. The split
Table.8 Strain values for Ferrocement panels tensile strength of geopolymer mortar has greater strength
compared with split tensile strength of cement mortar
specimens.
Table.8 Strain values for Ferrocement panels
Table 9. Split tensile test for cement mortar
Slab Reinforcement Specimens Strain
designation ID Description Split tensile
Load Strain
strength (MPa)
(kN)
Ferrocement Single layer of FC-1 6.27 11295 Days of curing 28
(FC) weld mesh FC-2 6.639 7902 Cylinder of 100 X 200mm 2.1
and double
layer of chicken FC-3 9.84 11226
mesh FC-4 8.084 10202 Table 10. Split tensile test for geopolymer mortar
Description Split tensile
strength (MPa)
Days of curing 28
Cylinder of 100 X 200mm 3.55

CRACKING
In both ferrocement panels and geo-ferrocrete panels the
cracking occurred around the mid span point. As the load is
gradually increased, the crack width started percolating
through ribs and many cracks were observed adjacent to the
center line crack. The cracking behavior also shows that the
maximum deflection of the panel was occurred at the mid
span.
Fig.11 (a), (b), (c), (d) Strain behavior of Ferrocement
panels

COMPRESSIVE STRENGTH TEST

It is a mechanical property to measure the maximum load the
cube can undergo before failure. The test was conducted
according to IS codal provision. The compressive strength of (a) (b) (c)
geopolymer mortar and cement were studied and results are
plotted. It shows that geopolymer mortar has early strength Fig.13 (a) cracking of ferrocement panel (b) cracking of
development and also good in compression loading. ferro-gopolymer panel specimens after testing

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RESULTS and DISCUSSION observed at 5.09kN with deflection 21.055mm. The

ultimate failure was for ferrocement panel was
 The geopolymer mortars gain more than 95% of its
observed at 9.849kN for FC-3 specimen.
28-day strength within 14- days. Comparatively the
cement mortar gains about 80% of its 28-day strength  Thus it gives a technical conclusion that the
within 14-days. This point concludes that the performance of ferrocement panels are good in
geopolymer mortars gain strength rapidly, unlike the bending, though the cement mortar matrix performance
case of cement mortars. has been moderate against direct compression
 According to the experimental works carried out, the
compressive strength of geopolymer mortar specimens
CONCLUSION
gave greater compressive strength at the age of 14 days
of more than 60Mpa, when compared with cement  The geopolymer mortar is cured under ambient
mortar specimens with 50Mpa at the age of 28days. It temperature conditions it doesn’t require water curing.
means the performance of geopolymer mortars against
 As water is a precious material, for the construction
compression are quite better than OPC mortars.
purpose cement mortar requires more amount of water
 The split tensile strength of geopolymer mortar and day by day there is reduction the water quantity to
specimens at the age 28days was found to be 3.55Mpa overcome that geopolymer mortar can be replaced with
and cement mortar was 2.1Mpa. In this type of cement mortar.
mechanical strength also the geopolymer performance
 Even though geo-ferrocrete panels are good in
is comparatively better.
compression and split tensile strength they are not more
 However, the flexural behaviour of ferrocement panels resistant against bending when compared with
were shown to be better when compared to that of geo- Ferrocement panels. As Ferrocement panels were good
ferrocrete panels. in bending.
 The load bearing capacity of ferrocement panels were  Maintaining of cover places a important role in strength
found to be relatively more and the initial cracking was gain, and load bearing capacity. Even though the crack
observed at 5.09kN with deflection 21.055mm. The was developed at lesser load. The increase in load was
ultimate failure was for ferrocement panel was observed due the distributed reinforcement.
observed at 9.849kN for FC-3 specimen.
 About 97% of strength development was observed in
 Thus it gives a technical conclusion that the geopolymer mortar at early ages of 14 days which is
performance of ferrocement panels are good in not observed in cement mortar specimens. The geo-
bending, though the cement mortar matrix performance ferrocrete panels were not good in bending even though
has been moderate against direct compression there was not much difference in the ultimate load
when compared with Ferrocement elements.
 The geopolymer mortars gain more than 95% of its 28-
day strength within 14- days. Comparatively the  Delay of initial crack is observed in Ferrocement panels
cement mortar gains about 80% of its 28-day strength compared with geo-ferrocrete which shows greater
within 14-days. This point concludes that the crack resistance behavior.
geopolymer mortars gain strength rapidly, unlike the
 Due to the simple cross section and flexibility and the
case of cement mortars.
panels are useful in precast construction with low cost
 According to the experimental works carried out, the housing schemes and emergency shelter housing for
compressive strength of geopolymer mortar specimens disaster affected areas.
gave greater compressive strength at the age of 14 days
of more than 60Mpa, when compared with cement
mortar specimens with 50Mpa at the age of 28days. It ACKNOWLEDGEMENTS
means the performance of geopolymer mortars against
compression are quite better than OPC mortars. The authors would like to thank The Director of CSIR –
Structural Engineering Research Centre for providing the
 The split tensile strength of geopolymer mortar necessary facilities and adequate resources to complete the
specimens at the age 28days was found to be 3.55Mpa work successfully.
and cement mortar was 2.1Mpa. In this type of
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