AT A GLANCE

 

FERROCEMENT AND LAMINATED CEMENTITIOUS COMPOSITES

by Antoine E. Naaman, Ph.D.
Fellow ACI; Fellow ASCE; Fellow PCI; Fellow IFS
Professor of Civil Engineering, University of Michigan, Ann Arbor

Hardcover; 372 pages; 160 figures and illustrations; 43 pages containing 120 photographs; design aids; bibliographic references; 7.25x9.5 in.

ISBN: 0-9674939-0-0; LCCN: 99-96382
Copyright 2000

US$ 75.00

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Ferrocement is truly the first invention of reinforced concrete, the most-used construction material in the world. It is a thin composite made with a cement based mortar matrix reinforced with closely spaced layers of relatively small diameter wire mesh. Since the mesh may be made of metallic or fiber reinforced polymeric materials, ferrocement also belongs to the family of thin laminated composites. Applications of ferrocement include marine and terrestrial structures such as boats, fishing vessels, barges, water tanks, silos, shells, monolithic and prefabricated housing structures. Ferrocement and Laminated Cementitious Composites is meant as a teaching text, a comprehensive source of information, and a basic reference. It emphasizes the fundamental concepts for the analysis and design of ferrocement and points out its particular characteristics vis-a-vis reinforced concrete, and fiber reinforced polymeric and cementitious composites. As such, it also covers thin reinforced concrete products and is an effective prerequisite to fiber reinforced concrete. The book offers a highly original approach to modeling tensile and bending behavior while keeping the theoretical concepts manageable, and underscoring the relationships between behavior, analysis, design, testing, and construction. Numerous examples are given (in both SI and US units) to illustrate the various concepts and methodologies described. A large number of figures, photos and graphs providing a wealth of synthesized and invaluable information are presented.

Ferrocement and Laminated Cementitious Composites is intended for students, engineers, architects and construction professionals. It is a prime choice as a text in advanced civil engineering materials courses, and in courses dealing with advanced brittle matrix composites. It can also be advantageously used in general civil and architectural course offerings. The material covered is an essential supplement to the breadth of knowledge and expertise of any professional involve in traditional reinforced and prestressed concrete applications. It is also a unique source for guiding amateur and self-help builders of ferrocement marine and terrestrial structures to select the proper materials and construction method to guarantee a sound structure. Ferrocement and Laminated Cementitious Composites is the only comprehensive book of its kind on the market.

 

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CONTENTS
 
Contents
Preface
Acknowledgments

Chapter 1 Introduction to Ferrocement
Chapter 2 Mechanical Properties of Ferrocement as Observed From Tests
Chapter 3 Modeling the Tensile Response of Ferrocement and Other Brittle Matrix Composites with Continuous Fibers
Chapter 4 Analysis and Design of Ferrocement in Bending
Chapter 5 Practical Design Guidelines
Chapter 6 Construction/Fabrication of Ferrocement
Chapter 7 Testing for Reinforcement and Composite Properties
Chapter 8 Cost Estimates of Typical Ferrocement Composites
Chapter 9 Ferrocement in Housing and Other Related Applications
Chapter 10 Advanced Materials and Concepts
Chapter 11 Prospects for Ferrocement Materials, Applications and Technology

Appendix A: Notation
Appendix B: Unit Conversions
Appendix C: References
Appendix D: Standard Meshes, Wires and Bars
Appendix E: Common Formulas for Beams
Index


DETAILED CONTENTS

Chapter 1 INTRODUCTION TO FERROCEMENT

Ferrocement: Definition and Historical Background / Introduction / Definition by ACI Committee 549 / Suggested Revised Definition / Applications of Ferrocement - Marine - Terrestrial - Repair and Rehabilitation / Constituent Materials of Ferrocement - Cement Based Matrix: Composition and Compressive Strength - Skeletal Steel - Mesh Reinforcement / Distinct Characteristics of Ferrocement versus Reinforced Concrete - Physical - Mechanical - Processing / Manufacturing - Maintenance and Repair / Similarities Between Ferrocement and Reinforced Concrete/ Volume Fraction of Reinforcement - Square or Rectangular Meshes - Example: Square Mesh - Any Mesh - Example: Expanded Metal Mesh - FRP Meshes - Example: FRP Mesh / Specific Surface of Reinforcement - Example: Reinforced Concrete versus Ferrocement / Distinctive Behavior of Ferrocement in Tension - Cracking and Multiple Cracking Behavior - Maximum Elongation at Failure - Stress at First Cracking - Influence of Specific Surface of Reinforcement / Apparent Modulus of the Mesh System / Ferrocement: a Composite and a Member of the Structural Concrete Family / Ferrocement versus Fiber Reinforced Polymeric Composites / Ferrocement as a Laminated Composite / Advantages of Ferrocement as a Construction Material.



Chapter 2 MECHANICAL PROPERTIES OF FERROCEMENT AS OBSERVED FROM TESTS

Introduction / Tensile Properties / First Cracking / Elastic Modulus In Tension / Uncracked Member / Cracked Member / Bending - Typical Behavior - Observations and Conclusions / Fatigue under Bending / Shear / Design for Shear / Compression / Impact – Impermeability / Leakage / Fire Resistance / Durability / Criteria for Selection and Use of Ferrocement.



Chapter 3 MODELING THE TENSILE RESPONSE OF FERROCEMENT AND OTHER BRITTLE MATRIX COMPOSITES WITH CONTINUOUS FIBERS

General Assumptions and Notation / Uncracked Tensile Member: Basic Mechanisms and Modeling / Stresses in Fiber and Matrix within Transition Length - Distance at which Equal Strains Occur: Transfer Distance - Stresses in Matrix and Reinforcement beyond the Transfer Distance - Load and Stresses at First Matrix Cracking - Minimum Volume Fraction of Reinforcement / Example: Uncracked Tensile Member - SI System - US System / Cracked Tensile Member: Basic Mechanisms and Modeling - Stresses in Matrix and Reinforcement at a Cracked Section - Stresses Between Two Cracks - Stresses at Yield and Ultimate - Minimum, Maximum, and Average Crack Spacing - Average Stress in Reinforcement and Matrix - Average Crack Width / Example: Cracked Ferrocement Tensile Member - SI System - US System / Experimental Observations Supporting Cracking Theory / Maximum Crack Width In Ferrocement Tensile Elements: ACI Guide Approach - US System - SI System - Example: Crack Width Using ACI Recommended Method / Elastic Modulus: Cracked and Uncracked Member - Uncracked Member - Upper Bound Solution - Cracked Member: Absolute Lower Bound Solution - Cracked Member: Suggested Approximate General Solution / Example: Prediction of Composite Stress-Strain Response - SI System - US System / Basic Properties as Random Variables / Particular Remarks for Ferrocement.



Chapter 4 ANALYSIS AND DESIGN OF FERROCEMENT IN BENDING

Notation / Differences in the Analysis/Design of Ferrocement with Conventional Reinforced Concrete / Proposed Remedies / Effective Area of Reinforcement / Typical Moment-Curvature Response / Analysis Methods for Bending under Service Loads - Flexure Formula: Uncracked Section - Transformed Area Method for the Cracked Section - Equilibrium and Compatibility Method for the Cracked Section - Moment versus Deflection Curve / Example: Cracked Section by the Transformed Area Method (SI System) - Welded Wire Mesh Reinforcement - Expanded Steel Mesh Reinforcement / Example: Cracked Section by the Transformed Area Method (US System) - Welded Wire Mesh Reinforcement - Expanded Steel Mesh Reinforcement / Analysis Methods for Nominal Bending Resistance - Compatibility Method Similar to Reinforced Concrete Columns - Example: Mn by the Compatibility Method (SI System) - Simplified Method Based on All Tensile Reinforcement Yielding - Example: Mn Assuming All Tensile Reinforcement Yielding (SI System) - Simplified Method Using Plastic Moment - Example: Mn Using Plastic Moment (SI System) - Simplified Method Using Design Chart or Prediction Equation - Example: Mn Using Prediction Equation (SI System) - Remarks on the Use of Simplified Methods / Additional Examples of Nominal Bending Resistance Using the Simplified Methods (SI System) - Using the Plastic Moment Approach - Using the Design Chart or Prediction Equation Approach - Using the All Tensile Reinforcement Yields Approach / Predictions of Crack Widths in Bending - Static or Monotonic Loading - Cyclic Fatigue Loading - Example: Crack Width in Bending / Equivalent Elastic Bending Strength (MOR) and Correlation with Tensile Strength - Modulus of Rupture (MOR) - Example: MOR Using Prediction Equation (SI System) - MOR versus Tensile Strength - Example: Ratio of Bending to Tensile Strength / Computation of Deflections - Deflection of Simply Supported Uncracked and Cracked Beams - Moment Deflection Relation / Concluding Remarks.



Chapter 5 PRACTICAL DESIGN GUIDELINES

Design Philosophy / General Design Approaches - USD, LSD, or LRFD - WSD or ASD / Design Approaches Applied to Ferrocement / Practical Design Guidelines to Insure Good Serviceability - Allowable Stresses under Maximum Service Load - Maximum Crack Width - Fatigue Life - Durability and Corrosion - Deflection Limitations / Practical Design Parameters for Ferrocement / Guidelines for Good Construction / Design Example: Tensile Element - Water Tank Wall / Design Example: Bending Element - Floor Sandwich Panel / Concluding Remarks.

Chapter 6 CONSTRUCTION - FABRICATION OF FERROCEMENT

Introduction / Mortar Placement / Construction Methods - Skeletal Armature Method - Closed Mold Method - Integral Mold Method - Open Mold Method / Special Manufacturing Techniques / Ferrocement Element versus Structure / Protective Surface Treatments / Current Reaches with and Notable Structures of Ferrocement.



Chapter 7 TESTING FOR REINFORCEMENT AND COMPOSITE PROPERTIES

Introduction / Recommended Tests - Compressive Strength and Static Modulus of Elasticity of Mortar - Tensile Test of the Mesh Reinforcement - Tensile Test of Ferrocement - Bending Test of Ferrocement / Efficiency Factor of Reinforcement - ho from Direct Tensile Tests - ho from Bending Tests with One Layer of Mesh - ho from Bending Tests with Several Layers of Mesh - Discussion Related to sry and Er - Test Sequence / Recommended Values for ho, sry and Er / Example of Computation of Er, hL, and sru from a Tensile Test / Example of Computation of Mesh Yield Strength, sry - Using a Composite Tensile Test - Using a Composite Bending Test / Example of Computation of Mesh Elastic Modulus from a Bending Test.



Chapter 8 COST ESTIMATES OF TYPICAL FERROCEMENT COMPOSITES

Introduction / Description of Cost Survey / Comparative Cost Results / Building and Construction Cost Indexes - Definition - Cost Correlation to the Present - Relative Importance of Labor and Materials Costs / Examples of Gross Cost Estimates Based on Past Experience / Remarks on Cost Reduction Measures.



Chapter 9 FERROCEMENT IN HOUSING AND RELATED APPLICATIONS

Introduction / Background: Ferrocement Housing Systems / Example of Ferrocement Panelized Housing System / System Criteria - Basis of Study- Panel System Developed - Types of Joints or Connections - Shear Type Joint - Moment Type Joint / Ferrocement Sandwich Panels / Manufactured Housing: Engineering Vision and Consumer’s Dream / Monolithic Ferrocement Auditorium / Ferrocement Water Tanks / Sunscreens / Concluding Remarks.



Chapter 10 ADVANCED MATERIALS AND CONCEPTS

Advanced or High Performance Materials // Fiber Reinforced Polymeric Meshes - Introduction - Significance - Advantages and Drawbacks - Type and Availability - Cost Considerations - Examples of FRP Meshes Tested - Test Parameters of Experimental Investigation - Typical Results - Influence of Number of Mesh Layers or Vr - Loading-Unloading Response - Effect of Production Process - Effect of Using Meshes with Low Elastic Modulus - Effect of Using a Fiber Mat - Conclusions on the Use of FRP Meshes with Conventional Cement Mortar Matrices // Hybrid Composites - Justification - Experimental Results - Effect of Adding Discontinuous Fibers with PVA Mesh - Effect of Adding Discontinuous Fibers with Carbon Mesh - Effect of Adding Discontinuous Fibers with Kevlar and Spectra Meshes - Conclusions on Using Hybrid Composites // Three-Dimensional (3-D) Meshes / Advanced Matrices - Inorganic Matrices - Concrete Polymer Composites // Self-Stressing Composites Motivation - Methods of Prestressing and Self-Stressing - Definition of Deformation Controlled Recovery Property (DCRP) - Why Self-Stressing Cementitious Composites and What Can Be Expected? - Advantages of Self-Stressing - Analytical Formulation - Typical Analytical Results - Experimental Results to Demonstrate the Concept / Concluding Remarks.



Chapter 11 PROSPECTS FOR FERROCEMENT MATERIALS, APPLICATIONS, AND TECHNOLOGY

Research Trends in Construction Materials / Prospects for Ferrocement Materials, Applications and Technology.



APPENDIX A: NOTATION

Notation: English Letters / Notation: Greek Letters / Abbrebiations / Abbreviations for Professional Organizations

APPENDIX B: UNIT CONVERSIONS

APPENDIX C: REFERENCES

General References - Symposia Proceedings on Ferrocement - Books - Background References - Sources of Information / References by Chapter // Close to 400 references in all.

APPENDIX D: STANDARD MESHES, WIRES AND BARS

APPENDIX E: COMMON FORMULAS FOR BEAMS

INDEX

 

 
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REVIEWS
 

"I have read almost everything written about ferrocement in the English language and can truthfully say: this book is the most comprehensive and authoritative treatment of ferrocement in existence."
Martin E. Iorns, Industrial Engineer, Member Editorial Board of the Journal of Ferrocement.


"Ferrocement and Laminated Cementitious Composites is a comprehensive source of information. The author has used his considerable expertise in giving a modern treatment to ferrocement. His emphasis on understanding the relationship between behavior, analysis and design is unique....The book offers perspectives and insights unparalleled in the existing literature on thin reinforced concrete products, and is an invaluable addition to the library of any professional involved in structural concrete."
Surendra P. Shah, Water P. Murphy Professor of Civil Engineering, Northwestern University, and Director NSF Center for Advanced Cement Based Materials.


"Indispensable book for engineers, architects, researchers, students and contractors interested in ferrocement and thin reinforced concrete products. The author has provided a much needed single source textbook that consolidates a broad coverage of information, whether on state-of-the-art, design, construction, cost, applications or future potential of ferrocement and hybrid composites."
Gordon B. Batson, Emeritus Professor of Civil Engineering, Clarkson University, former Chairman ACI Committee on Ferrocement.


"A unique and comprehensive treatise of laminated cement composites covering materials, fabrication techniques, analysis and design of structural components and systems, and including the latest developments on high performance composites."
P.N. Balaguru, Professor of Civil Engineering, Rutgers University, Former Chairman of ACI Committee 549 on Ferrocement.


"It must certainly be the most comprehensive work in its field. Even sculptors, who may not understand the mathematics, can derive sculptural applications from the many excellent illustrations and verbal explanations and can learn the basics about how and where to place the steel."
Lynn Olson, Sculptor, Clausen Lane, Valparaiso, Indiana.


"This detailed and comprehensive book enables an appreciation to be made of ferrocement from theoretical and practical considerations. The many good examples of ferrocement are brought together indicating the undoubted range and breadth of the material and its potential uses which good design and implementation can bring about. It is an indispensable ferrocement companion."
Patrick J. Jennings, Director of Engineering, NCL Stewart Scott Ltd., London, U.K.


"This book is indeed the finest and most comprehensive book on the subject that I know of. Professor Naaman has pulled together his 25+ years of experience and research in the ferrocement field and come up with a textbook of ferrocement. This book will most likely become the standard textbook for the teaching field when it comes to ferrocement.
Paul Sarnstrom, Host, www.ferrocement.net, Montrose, Colorado.


"I have been collecting books on ferrocement for five years. I recently purchased "Ferrocement and Laminated Cementitious Composites. I'm certain it will inspire the design of many new products and structures. In my opinion, it is destined to become the "ferrocement bible".
David B. Smith, Spartanburg , S.C.


"This book is the first to bring together the wealth of information currently available and presents it in a digestible format. Written in an extremely readable style, the book takes a reader through the historical and early technical background to a modern analytical method with abundant worked examples. More practical information regarding design and construction is then presented with further detail on the specific topics of testing, costing and housing. A final section on advanced materials and concepts provides a sneak preview into a possible future.
Paul Nedwell, University of Manchester Institute of Science and Technology, Manchester, U.K.


Click for detailed reviews by:

Review by G. Batson - RILEM Journal of Materials and Structures
 

Review by S. P. Shah - PCI Journal
 

Review by P. Nedwell
 

Review by Editor - Concrete International


PLEASE SEND US YOUR REVIEW COMMENTS:

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LINKS
 

Here are web sites containing a wealth of information about Ferrocement:
www.clair.ait.ac.th/ific/ - - This is the site of the International Ferrocement Information Center located at the Asian Institute of Technology in Bangkok. It is also the main link of the International Ferrocement Society.
www.ferrocement.org - - This is the site of the International Ferrocement Society based in Bangkok, Thailand.
www.ferrocement.net - - This is a ferrocement news, discussion group, and information site.
www.ferrocement.com - - This is a ferrocement news and information site.
www.aci-int.org - - This is the site of the American Concrete Institute - International, where information about all aspects of concrete materials and structures including ferrocement can be found. ACI International also has an on-line bookstore from where books and reports can be ordered using a credit card.
In Association with Amazon.com


Following is a list of selected titles on fiber reinforced composites, particularly cement or concrete based composites.

  • 1999 High Performance Fiber Reinforced Cement Composites - HPFRCC 3 H.W. Reinhardt (Editor), A.E. Naaman (Editor) / Hardcover / Published 1999
  • 1999 Engineered Interfaces in Fiber-Reinforced Composites J.K. Kim / Hardcover / Published 1999
  • 1999 3-D Textile Reinforcements in Composite Materials Antonio Miravete (Editor) / Hardcover / Published 1999

  • 1998 Engineered Interfaces in Fiber Reinforced Composites Jang-Kyo Kim, Y.W. Mai / Hardcover / Published 1998
  • 1998 Guide to short Fiber Reinforced Plastics Roger F. Jones, et al / Paperback / Published 1998
  • 1998 Engineered Interfaces in Fiber Reinforced Composites Jang-Kyo Kim, Y.W. Mai / Hardcover / Published 1998

  • 1997 Dynamic Loading and Characterization of Fiber-Reinforced Composites Shive K. Chaturvedi (contributor), Robert L. Sierakowski / paperback / published 1997
  • 1997 Stress Analysis of Fiber-Reinforced Composite Materials Michael Hyer, Scott R. White (contributor) / Hardcover / Published 1997
  • 1997 Composites Engineering Handbook P.K. Malick (Editor) / Hardcover / Published 1997
  • 1997 Databook on Mechanical and Thermophysical Properties of Fiber-Reinforced Ceramic Matrix Composites Christian X. Campbell, Said K. El-Rahaiby / Hardcover / Published 1997
  • 1997 Mechanics of Fibrous Composites Carl T. Herakovich / Hardcover / Published 1997

  • 1996 High Performance Fiber Reinforced Cement Composites - HPFRCC 2 A.E. Naaman (Editor), H.W. Reinhardt (Editor) / Hardcover / Published 1996
  • 1996 Fiber, Matrix, and Interface Properties (Astm Special Technical Publication, 1290.) C.J. Spragg(Editor), Lawrence T. Drzal / Paperback / Published 1996
  • 1996 Micromechanics of Composites: Composite Properties of Fibre and Matrix Constituents Kuno K.U. Stellbrink / Paperback / Published 1996

  • 1995 Carbon Fibers: Formation, Structure, and Properties Leighton H. Peebles / Hardcover / Published 1995
  • 1994 Carbon Fiber Composites Deborah D.L. Chung / Hardcover / Published 1994
  • 1994 Design and Manufacture of Composite Structures Geoff Eckold / Hardcover / Published 1994
  • 1994 Engineering with Fibre-Polymer Laminates Peter C. Powell / Paperback / Published 1994
  • 1993 Fiber-reinforced Composites P.K. Malick / Hardcover / Published 1993
  • 1992 High Performance Fiber Reinforced Cement Composites - HPFRCC 1 H.W. Reinhardt (Editor), A.E. Naaman (Editor) / Hardcover / Published 1992
  • 1992 Fibre reinforced cement and concrete: Proceedings of the fourth international symposium held by RILEM (the International Union of Testing and Research Laboratories for Materials and Structures) and organized by the Department of Mechanical and Process Engineering, University of Sheffield, UK, Sheffield, July 20-23, 1992
  • 1992 Fiber-Reinforced Cement Composites Perumalsamy N. Balaguru, Surendra P. Shah / Hardcover / Published 1992
  • 1992 Ceramic-Matrix Composites R. Warren (Editor) / Hardcover / Published 1992
  • 1991 Fiber-Reinforced Cementitious Materials: Symposium Held November 26-28, 1990, Boston, Massachusetts, USA (Materials Research Society Symposium Pr) Sidney Miness (Editor), Jan Skalny (Editor) / Hardcover / Published 1991
  • 1990 Analysis and Performance of Fiber Composites (Spe Monographs) Bhagwan D. Agarwal, Lawrence J. Broutman (contributor) / Hardcover / Published 1990
  • 1990 Fibre Reinforced Cementitious Composites Arnon Bentur, Sidney Mindess / Hardcover / Published 1990
  • 1989 Fibre Reinforced Cements and Concretes: Recent Developments R.N. Swamy (Editor), B. Barr (Editor) / Hardcover / Published 1989

 

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