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549.1R-93 Guide for the Design, Construction, and Repair Of ACI 549.1R-93 (Reapproved 1999) Guide for the Design, Construction, and Repair ofFerrocement Reported by ACICommittee 549 Gordon B. Batson* Ronald F. Zollo* Chairman Secretary Perumalsamy N. Balaguru* Colin D. Johnston Narayan Swamy Jose O. Castro Antoine E. Naaman (former Chairman) * Ben L. Tilsen Antonio J. Guerra James P. Romualdi Robert B. Williamson Martin E. Iorns* Surendra P. Shah Rogerio C. Zubieta * Principal authors The following associate members of Committee 549 contributed to the preparation of this report: Shuaib H. Ahmad, Douglas Alexander, Antonio Nanni, Ricardo P. Pama, P. Paramasivam, Sherwood P. Prawel, and Andrei M. Reinhorn. Members of the Committee voting on the 1993 revisions: P.N. Balaguru Parviz Soroushian Chairman Secretary M. Arockiasamy Martin E. Iorns Surendra P. Shah Nemkumar Banthia Colin D. Johnston Narayan Swamy Gordon B. Batson Mohammad Mansur Ben L. Tilsen Jose O. Castro John L Mulder Methi Wecharatana James I. Daniel Antoine E. Naaman Robert B. Williamson David M. Gale Antonio Nanni Robert C. Zellers Antonio J. Guerra D.V. Reddy Ronald F. Zollo Lloyd Hackman James P. Romualdi Rogerio C. Zubieta This guide supplements two earlier publications (ACI 549R, State-of-the- l.l-Scope Art Report of Ferrocement, and SP-61, Ferrocement-Materials and 1.2-Approval to use procedures Applications). It provides technical information on materials and material selection, design criteria and approaches, construction methods, main- tenance and repair procedures, and testing. The objectives are to promote Chapter 2-Terminology, pg. 549.lR-2 the more effective use of ferrocement in terrestrial structures, provide 2.1-Reinforcement parameters architects and engineers with the necessary tools to specify, and use ferro- 2.2-Notation cement, and provide owners or their representutives with a reference docu- 2.3-Definitions ment to check the acceptability of ferrocement alternative in a given ap- plication. Chapter 3-Materials, pg. 549.1R-4 Keywords: admixtures; cements; composite materials; construction; construction 3.1-Matrix materials; ferrocement; fibers; flexural strength, maintenance; metals; modulus of 3.2-Reinforcement elasticity; reinforced concrete; reinforcing materials; repairs; structural design; tension tests; welded wire fabric. Chapter 4-Design, pg. 549.1R.8 CONTENTS 4.1-Design methods 4.2-Strength requirements Chapter l-General, pg. 549.1R-2 4.3-Service load design 4.4-Serviceability 4.5-Particular design parameters ACI Committee Reports, Guides, Standard Practices, and Commentaries are intended for guidance in designing, plan- ACI 549.lR-93 supersedes ACI 549.1R-88 and became effective November 1, ning, executing, or inspecting construction and in preparing 1993. specifications. References to these documents shall not be Copyright 0 1988, American Concrete Institute. made in the Project Documents. If items found in these All rights reserved including rights of reproduction and use in any form or by any means, including the making of copies by any photo process, or by any elec- documents are desired to be a part of the Project Docu- tronic or mechanical device, printed, written, or oral, or recording for sound or ments, they should be phrased in mandatory language and visual reproduction or for use in any knowledge or retrieval system or device, incorporated into the Project Documents. unless permission in writing is obtained from the copyright proprietors. 549.1R-l 549.1R-2 ACI COMMITTEE REPORT 4.6-Examples closely spaced multiple layers of mesh and/or small- 4.7-Design aids diameter rods completely infiltrated with, or encapsul- ated, in mortar. The most common type of reinforcement Chapter 5-Fabrication, pg. 549.1R-11 is steel mesh. Other materials such as selected organic, 5.1-General requirements natural, or synthetic fibers may be combined with metal- 5.2-Construction methods lic mesh. This guide addresses only the use of steel rein- forcement in a hydraulic cement mortar matrix. Chapter 6-Maintenance and repair, pg. 549.lR-15 Applications of ferrocement are numerous, especially 6.1-Introduction in structures or structural components where self-help or 6.2-Blemish and stain removal low levels of skills are required. Besides boats and 6.3-Protective surface treatments marine structures, ferrocement is used for housing units, 6.4-Damage repair water tanks, grain silos, flat or corrugated roofing sheets, 6.5-Repair materials irrigation channels, and the like (see ACI 549R). 6.6-Repair procedure 1.2-Approval for use in design and construction Chapter 7-Testing, pg. 549.lR-20 Use of ferrocement and the procedures covered in this 7.1-Test methods guide may require approval by the authority or govern- mental agency having jurisdiction over the project. Chapter 8-References, pg. 549.1R-22 8.1-Recommended references 8.2-Cited references CHAPTER 2-TERMINOLOGY Appendix A-Calculation of volume fraction of rein- 2.1-Reinforcing parameters forcement, pg. 549.1R-25 Three parameters are commonly used in characterizing the reinforcement in ferrocement applications: the vol- Appendix B-Flexural strength analysis of ferrocement ume fraction, the specific surface of reinforcement, and sections, pg. 549.1R-25 the effective modulus of the reinforcement. 2.1.1 Volume fraction of reinforcement Vf-Vf is the Appendix C-SimpIified design aids, pg. 549,1R-28 total volume of reinforcement divided by the volume of composite (reinforcement and matrix). For a composite Appendix D-Surface treatment for ferrocement struc- reinforced with meshes with square openings, Vf is equal- tures attacked by commonly used chemicals, pg. ly divided into Vfl and Vft for the longitudinal and trans- 549.1R-29 verse directions, respectively. For other types of rein- forcement, such as expanded metal, Vfl and Vft may be unequal. Examples of computation of Vf are shown in CHAPTER l-GENERAL Appendix A. 2.1.2 Specific surface of reinforcement Sr-Sr is the total l.l-Scope bonded area of reinforcement (interface area or area of This guide is based on technical information as- the steel that comes in contact with the mortar) divided sembled by ACI Committee 549, Ferrocement, from cur- by the volume of composite. Sr is not to be confused with rent practice, developments, and advances in the field of the surface area of reinforcement divided by the volume ferrocement around the world. It represents a practical of reinforcement. For a composite using square meshes, supplement to the state-of-the-art report (ACI 549R) Sr is divided equally into Srl and Srt in the longitudinal published earlier by the committee. The guide covers and transverse directions, respectively. materials for ferrocement, materials selection, and stan- For a ferrocement plate of width b and depth h, the dards; design criteria and approaches; construction meth- specific surface of reinforcement can be computed from: ods; maintenance and repair procedures; and testing. The objectives of this guide are to promote the effec- c 0 S =7 t (2-1) tive use of ferrocement in terrestrial structures, provide bh architects and engineers with the necessary tools to spe- cify and use ferrocement, and provide owners or their re- in which x0 is the total surface area of bonded rein- presentatives with a reference document to check the forcement per unit length. acceptability of a ferrocement alternative in a given 2.1.3 Relation between Sr and Vf-The relation between application. This guide is consistent with ACI Building S and V when square-grid wire meshes are used is Code Requirements for Reinforced Concrete (ACI 318) r f except for the special characteristics of ferrocement, such 4vf as reinforcement cover and limits on deflection. Sf =- Ferrocement is a form of reinforced concrete using db FERROCEMENT 549.1R-3 where d is the diameter of the wire. For other types of b f Y = yield strength of mesh reinforcement or rein- reinforcement, such as expanded metal, Srl and Srt may forcing bars be unequal. h thickness of ferrocement section 2.1.3 Effective modulus of the reinforcement-Although Mn = nominal moment strength the definitions of most ferrocement properties are the N n = nominal tensile strength same as for reinforced concrete, one property that may N = number of layers of mesh; nominal resistance be different is the effective modulus of the reinforcing nr = modular ratio of reinforcement system Er. This is because the elastic modulus of a mesh s = mesh opening or size (steel or other) is not necessarily the same as the elastic Sr = specific surface of reinforcement modulus of the filament (wire or other) from which it is Srl = specific surface of reinforcement in the longi- made. In a woven steel mesh, weaving imparts an undul- tudinal direction = ating profile to the wires. When tested in tension, the Srt specific surface of reinforcement in the trans- woven mesh made from these wires stretches more than verse direction a similar welded mesh made from identical straight wires. Vf = volume fraction of reinforcement Hence, the woven mesh behaves as if it has a lower elas- Vfi = volume fraction of reinforcement formesh tic modulus than that of the steel wires from which it is layer i made. V = volume fraction of reinforcement in the longi- fl In addition, when a woven mesh is embedded in a tudinal direction mortar matrix and tends to straighten under tension, the Vft = volume fraction of reinforcement in the trans- matrix resists the straightening, leading to a form of verse direction tension stiffening.A similar behavior occurs with PI = factor defining depth of rectangular stress expanded metal mesh (lath) and hexagonal mesh. To block (ACI 318, Section 10.2.7.3) account for the above effects, the term “effective modulus rl = global efficiency factor of embedded rein- of the reinforcing system” Er is used. For welded steel forcement in resisting tension or tensile- meshes, Er may be taken equal to the elastic modulus of bending loads the steel wires; for other meshes, Er may be determined 772 = value of q when the load or stress is applied from tensile tests on the ferrocement composite as ex- along the longitudinal direction of the mesh plained in Chapter 7.
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