ACI 549R-2018 Report on Ferrocement.pdf

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1、Report on Ferrocement Reported by ACI Committee 549 ACI 549R-18First Printing January 2018 ISBN: 978-1-945487-95-8 Report on Ferrocement Copyright by the American Concrete Institute, Farmington Hills, MI. All rights reserved. This material may not be reproduced or copied, in whole or part, in any pr

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11、n Concrete Institute 38800 Country Club Drive Farmington Hills, MI 48331 Phone: +1.248.848.3700 Fax: +1.248.848.3701 www.concrete.orgThis report provides an overview of the history, formulation, construction, and applications of ferrocement. The focus of this report is to create an awareness in engi

12、neers, architects, and poten- tial end-users of the characteristics and capabilities of ferrocement. Keywords: compressive strength; construction materials; crack width; ferrocement; fibers; flexural strength; mechanical properties; reinforced concrete; welded wire reinforcement. CONTENTS CHAPTER 1I

13、NTRODUCTION AND SCOPE, p. 1 1.1Introduction, p. 1 1.2Scope, p. 2 CHAPTER 2DEFINITIONS, p. 2 CHAPTER 3HISTORY, p. 2 CHAPTER 4COMPOSITION AND CONSTRUCTION, p. 4 4.1Basic matrix components, p. 4 4.2Reinforcements, p. 4 4.3Manufacturing techniques, p. 4 CHAPTER 5FERROCEMENT APPLICATIONS, p. 7 5.1Overvie

14、w, p. 7 5.2Future trends and potential uses, p. 8 CHAPTER 6REFERENCES, p. 9 Authored references, p. 10 APPENDIX ACASE STUDIES, p. 12 A.1Yanbu Cement Company, p. 12 A.2Apicorp Headquarters roof and soffit panels, p. 15 A.3Sustainable Serbian house, p. 19 A.4Prefabricated Serbian warehouse/multi-use b

15、uilding, p. 21 CHAPTER 1INTRODUCTION AND SCOPE 1.1Introduction Ferrocement is a form of reinforced concrete that differs from conventional reinforced or prestressed concrete primarily by the manner in which the reinforcing elements are dispersed and arranged. It consists of closely spaced, multiple

16、layers of mesh or fine rods completely embedded in cementitious mortar. A composite material is formed that behaves differently from conventional reinforced concrete in strength, deformation, and potential applications, and thus is classified as a separate and distinct material. It can be formed int

17、o thin panels or sections, mostly less than 1 in. (25 mm) thick, with only a thin mortar cover over the outermost layers of reinforcement. Unlike conventional Antonio Nanni, Chair Corina-Maria Aldea, Secretary ACI 549R-18 Report on Ferrocement Reported by ACI Committee 549 Nemkumar Banthia Christian

18、 Carloni Paolo Casadei Antonio De Luca Michael E. Driver Ashish Dubey Mahmut Ekenel Brad L. Erickson Garth J. Fallis John Jones* Barzin Mobasher Hani H. Nassif James E. Patterson Alva Peled Larry Rowland Surendra P. Shah Yixin Shao Lesley H. Sneed J. Gustavo Tumialan Consulting Members Gordon B. Bat

19、son James I. Daniel Antoine E. Naaman Paul Nedwell P. Paramasivam Parviz Soroushian * Chair of subcommittee that prepared this report Members of subcommittee that prepared this report. ACI Committee Reports, Guides, and Commentaries are intended for guidance in planning, designing, executing, and in

20、specting construction. This document is intended for the use of individuals who are competent to evaluate the significance and limitations of its content and recommendations and who will accept responsibility for the application of the material it contains. The American Concrete Institute disclaims

21、any and all responsibility for the stated principles. The Institute shall not be liable for any loss or damage arising therefrom. Reference to this document shall not be made in contract documents. If items found in this document are desired by the Architect/Engineer to be a part of the contract doc

22、uments, they shall be restated in mandatory language for incorporation by the Architect/Engineer. ACI 549R-18 supersedes ACI 549R-97 and was adopted and published January 2018. Copyright 2018, American Concrete Institute. All rights reserved including rights of reproduction and use in any form or by

23、 any means, including the making of copies by any photo process, or by electronic or mechanical device, printed, written, or oral, or recording for sound or visual reproduction or for use in any knowledge or retrieval system or device, unless permission in writing is obtained from the copyright prop

24、rietors. 1concrete, ferrocement reinforcement can be assembled into its final desired shape and the mortar plastered directly in place without the use of a form. The term “ferrocement” implies the combination of a ferrous reinforcement embedded in a cementitious matrix, yet there are characteristics

25、 of ferrocement that can be achieved with reinforcement other than steel meshes or rods. The use of nonmetallic mesh is being explored by several researchers around the world (Brameshuber 2015). Such meshes include woven alkali-resistant glass; organic woven fabrics such as polypropylene; and organi

26、c natural fabrics made with jute, burlap, or bamboo fibers. Therefore, the term “ferrocement” currently includes material other than steel as reinforcement. The definition for ferrocement has developed over the years to reflect advances in technology and practice. IFS 10-01 describes it as: a type o

27、f reinforced concrete commonly constructed of hydraulic cement mortar reinforced with closely spaced layers of relatively small wire diameter mesh. The mesh may be made of metallic or other suitable materials. The fineness of the mortar mixture and its composition should be compatible with the openi

28、ng and tightness of the reinforcing system it is meant to encapsulate. The matrix may contain discontinuous fibers. 1.2Scope This report includes the history, development, and appli- cations of ferrocement together with composition and construction. Appendix A of this report provides several case st

29、udies of ferrocement applications. CHAPTER 2DEFINITIONS ACI provides a comprehensive list of definitions through an online resource, “ACI Concrete Terminology.” CHAPTER 3HISTORY The origins of ferrocement can be traced to the work of Jean Louis Lambot who, in 1855, filed a patent for a material he c

30、alled ferciment (Naaman 2000), which he claimed could replace wood in construction. He made numerous items, including two boats, one of which can be seen in Fig. 3a. Other contemporary researchers were looking at reinforcing of cement-based matrix with metallic reinforcement. Due to the difficulties

31、 in producing suitable wire reinforcement, the larger bars became popular and reinforced concrete was produced as we know it today. Ferrocement, however, had a niche following and became a popular method for constructing boats, as shown in Fig. 3b. Following the Second World War, Italian architect a

32、nd engineer Pier Luigi Nervi developed the material for both marine and terrestrial applications with considerable success, as seen in Fig. 3c of his yacht, “Nanelle” (Huxtable 1960). Figure 3d shows an early warehouse and Fig. 3e shows the Turin Exhibition Hall roof. Further development moved to Ne

33、w Zealand where there was a thriving boat building and pontoon industry. In 1972, the National Academy of Sciences, through its Board on Science and Technology for International Devel- opment, established the Ad Hoc Panel on the Utilization of Ferrocement in Developing Countries. The report of the p

34、anel (National Academy of Sciences 1973) stimulated interest in non-marine applications of this versatile material. This led directly to the founding of the International Ferroce- ment Information Center (IFIC) at the Asian Institute of Tech- nology, Bangkok, Thailand, in October 1976. In collabora-

35、 tion with the New Zealand Ferro Cement Marine Association (NZFCMA), the IFIC started publishing a quarterly journal, The Journal of Ferrocement. The IFIC developed outreach and training programs, and hosted the Second (Austriaco et al. 1985) and Eighth (Nimityongskul 2006) International Symposia. U

36、nfortunately, through lack of funding, IFIC ceased production of the publication in 2006, and following intensive flooding in 2011, most of the remaining archive has been destroyed. A significant body of work, however, has been gathered from enthusiasts around the world and is held at the University

37、 of Manchester in the United Kingdom, where an electronic archive is being created. Fig. 3aLambot s boat. Fig. 3bEarly boat. American Concrete Institute Copyrighted Material www.concrete.org 2 REPORT ON FERROCEMENT (ACI 549R-18)Academic interest in ferrocement started to increase in the 1960s and 19

38、70s with the work of Professor Surendra Shah and his team at the University of Chicago. Team member Antoine Naaman became a world leader and proponent for the material, and was instrumental in promoting research across the globe from his base at the University of Michigan in Ann Arbor, MI. ACI Commi

39、ttee 549, “Thin Reinforced Cementitious Prod- ucts and Ferrocement,” was organized in 1974 and given the mission to study and report on the engineering properties, construction practices, and practical applications of ferroce- ment, and to develop guidelines for ferrocement construction. The first i

40、nternational meeting on ferrocement was held during the 1978 ACI Convention in Toronto, ON, Canada. From this came SP-61. RILEM organized a Conference in Bergamo, Italy, in 1981 (ISMES 1981), but by the time the Second International Symposium on Ferrocement was held in Bangkok, Thailand, in 1985 (Au

41、striaco et al. 1985), both the U.S. and European streams had come together. Subse- quent symposia have been held in Delhi, India (Kaushik and Gupta 1988); Havana, Cuba (Rivas 1991; Rivas et al. 2012); Manchester, UK (Nedwell and Swamy 1994); Ann Arbor, MI (Naaman 1998); Singapore (Mansur and Ong 200

42、1); Bangkok, Thailand (Nimityongskul 2006); Bali, Indonesia (Djausal et al. 2009); and Aachen, Germany (Brameshuber 2015). The International Ferrocement Society (IFS) was formed in 1991, and in 2001 produced the “Ferrocement Model Code” (IFS 10-01), which provided engineers with a docu- ment on whic

43、h to base their ferrocement design. In 1999, the “Ferrocement Education Network” was founded as an internet-based discussion group: www.ferro- . It is an independent venture mainly aimed at practitioners and enthusiasts. Books on ferrocement had previously been mainly self- help manuals (Abercrombie

44、 1977), boat books (Greenfield 1978), or foreign language publications (de Hanai 1992). Naaman (2000) produced Ferrocement and Laminated Cementitious Composites, which has become the textbook of choice around the world. CHAPTER 4COMPOSITION AND CONSTRUCTION 4.1Basic matrix components Basic component

45、s for the matrix are sand, cementitious material, and water. The sand type could vary depending on whether the matrix is to be hand- or machine-applied, although usually it is a manufactured sand passing a No. 8 (2.36 mm) sieve. Cementitious material may be of any recognized grade, although ordinary

46、 portland cement is the most widely used. Water should be of potable quality. The most popular sand-to-cementitious materials ratio is 2:1 by weight with the range extending between 3:2 and 3:1. The Fig. 3cNervi s yacht “Nanelle.” Fig. 3dNervi Bologna tobacco store. Fig. 3eNervi Turin Exhibition Hal

47、l. American Concrete Institute Copyrighted Material www.concrete.orgREPORT ON FERROCEMENT (ACI 549R-18) 3water-cementitious materials ratio (w/cm) is between 0.35 and 0.6, the lower only being achievable with admixtures. Developments with additives and admixtures over the years have reduced the poro

48、sity and increased the strength of the matrix. Supplementary materials such as silica fume, fly ash, and slag cement help densify the matrix, and use of high-range water-reducing admixtures has allowed strengths up to 11,000 psi (75 MPa) to be regularly achieved. Air entrainment agents, which are so

49、metimes included in the cement, improve cohesion and provide resistance to cycles of freezing and thawing. Care should be taken, however, to compensate for the reduction in strength that will follow 5.5 percent reduction in strength for each 1 percent air (Teychenne et al. 1988). The most recent development has been in self-consolidating matrixes; however, these are only suitable for horizontal molded applications. 4.2Reinforcements 4.2.1 Skeletal steelIf an armature is used, it is usually made of 0.25 to 0.375 in. (6 to 1