THIS WAS THE PROJECT CARRIED OUT BY OUR TEAM AS A FINAL YEAR PROJECT. IN THIS PROJECT STEEL FIBERS WAS INDUCED ALONG WITH CEMENT MATRIX TO INCREASE THE DURABILITY, CRACK RESISTANCE AND FLEXURAL STRENGTH OF FERROCEMENT BLOCKS. THESE BLOCKS HAS MORE LATERAL STABILITY THAN ORDINARY BRICKS

1. UNDER THE GUIDANCE OF
Mr. G.A. SATISH
ASSOCIATE PROFESSOR
DEPARTMENT OF CIVIL ENGINEERING
PRESENTED BY,
ABHISHEKA.T 1VI15CV002
MAHIMA SHARADA.R 1VI15CV020
SUJAN.M.E 1VI15CV040
ARCHANA.Y.V 1VI16CV401
FERROCEMENT BLOCK AS A MASONRY UNIT

2. 1. General
• Ferrocement is a construction material having superior qualities of crack control, resistance to impact and toughness
due to close spacing and uniform dispersion of steel fibers within the matrix.
• Over the years Ferrocement gained good response for its superior and enhanced performance, here we have added
various percentages of steel fibers to the ferrocement which increases the flexural strength ,resistance to cracks and it
will be of low self weight, more durable and hence enhances the overall performance.
2. Definition
• Ferrocement is the combination of materials consisting of cement mortar as the matrix and fine steel meshes in
layers as reinforcement .It has been concluded as a highly versatile construction material. This helps in
improving mechanical properties.
• Fiber reinforced cement is containing fibrous material which increases the structural integrity of matrix. It
contains short discrete fibers which are uniformly distributed in matrix and are randomly oriented.
INTRODUCTION
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 2

3. OBJECTIVES
• To provide an alternate building block to replace bricks for two reasons:
a) Traditional bricks are consuming large quantity of Alluvial soil which is suitable for
growing vegetation because of rich nutrients in the soil. Statistics show that by the year 2060 if
alluvial soil is continuously used for brick manufacturing there may be insufficient soil available
to grow vegetation.
b) To provide earthquake resisting masonry block instead of normal bricks.
• The objective is to cast a fibers reinforced ferrocement building block and investigate its
behavior in compression and Flexural strength.
• To compare the performance of Ferrocement Masonry blocks with Table moulded bricks.
• To analyse the cost of fibers reinforced ferrocement blocks with normal bricks.
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 3

4. 1. Aditya Dubey , Prof. Anubhav Rai:
Experimental behavior of concrete under compression load with steel fiber and Ferro-cement was studied .This
research has shown that the Steel fiber and Ferro-cement have potential to produce high performance of concrete
and it will also improve the characteristic properties.Concrete under compression with steel fiber and Ferro-cement.
The mix design water cement ratio is 0.50. The thesis consists of casting and testing of 35 cylinders
(300mmX150mm) and 15 cubes(150x150x150mm) which were casted in 6 batches.. Out of 6 batches 1st batch
was casted with 0 mesh and 0 fiber, 2nd with 0 mesh and 0.5% fiber, 3rd with 1 mesh and 0% fiber , 4th with 1
mesh and 0.5% fiber, 5th with 2 mesh of 0 fiber and lastly 6th with 2 mesh and 0.5% fiber 2 extra specimens were
prepared one with 0 mesh , fiber and second with 0 mesh, 0.5% fiber. This thesis has shown that the steel fiber and
Ferro-cement has following observation that the maximum ultimate strain is for the cube specimen with 0.5% fiber
concrete the compressive strength improved by 16% when compared with cube specimen with plane concrete only
is necessary criteria for absorbing the energy. This research has shown that the Steel fiber and Ferro-cement have
potential to produce high performance of concrete and it will also improve the characteristic properties
LITERATURE REVIEW
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 4

5. 3. Dr.Abdulkader G. Anwar:
Here ferrocement blocks in addition to wire mesh were investigated experimentally under compressive strength.
Ferrocement blocks or masonry blocks are a type of thin concrete made of cement sand matrix with closely spaced
relatively small wire meshes.A total of nineblocks were constructed and tested under compressive load. The
dimensions of hollow blocks were (400x200x200) mm. The main parameters considered in the present investigation
were the number of wire mesh layers (2), and type of constituent materials (mix proportions). The behavior of block
models under compressive loading was observed by reading the loads and observing the initial and crack patterns and
mode of failure. It is concluded that the compressive strength of ferrocement blocks having (2 wire meshes) is
considerably higher than that of mortar blockswithout mesh layers only by about (73.4 %). The behavior is less
significantly affected when wire mesh are
added to ferrocement blocks with (2 mesh layers), the increase was about (57%) with concrete blocks, and finally the
presence of wire mesh reinforcement in the blocks decreases the water absorption compared with the corresponding
concrete blocks.
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 5

6. 2. Mr. Sahan A, Mr. Sumanth, Mr. Vachan Shetty:
Here ferrocement blocks in addition to wire mesh were investigated experimentally under
compressive strength and flexural strength.
Ferro-cement contains closely spaced one or more than one layer of mesh or fine rods
embedded in cement mortar which is mix of calculated amount of water, cement and sand.
Fibre reinforced Ferro-cement is the mixture of Ferrocement and fibre. Adding fibre in Ferro-
cement reduces the micro crack and prevents the propagation of crack development. It
increases compressive strength and flexural strength of Ferro- cement, enhances the elastic
modulus and decrease brittleness. The experimental investigation had carried out to compare
the flexural strength and compressive strength with and without use of the fibres and it has
proved that the compressive strength and flexural strength, the values were found on the 28
days which justifies that the value increases and then on further addition of fibre it
decreases.Fibres acts like secondary reinforcement. 28 days of curing gives more strength than
7 days of curing. It indicates that increase in curing time has an appreciably effect in increasing
the strength of Ferrocement with and without using fibre.
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 6

7. Summary of Literature:
• From the above literature papers we can summarize that ferrocement blocks with steel fiber
being light material is used to enhance the performance of ferrocement which performs
better than to the ordinary brick masonry.
• Consumes very less materials and is more resistant to withstand the earthquake and wind
loads and also enhances the properties like improvement in flexural behavior, impact
resistance, good compressive strength and also shows improved resistance for the
earthquake and wind load.
• As the number of mesh increases, the ultimate strength is increased but up to certain point.
• From the papers many advantages of steel fiber reinforced cement and its application for
different purpose are also given. In general, ferrocement with steel fibers improves Flexural
strength with the inclusion of steel fibers in ferrocement.
• However, maximum gain in strength of ferrocement is found to depend upon the amount of
fiber content and number of layers of steel meshes used.
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 7

8. 1. General:
The properties of ferrocement depend on the materials used for the manufacturing ferrocement element. It is
essential to charactarize the materials used. Materials used for workable mortar are cement, M-sand and water. The
materials used for steel fiber reinforced ferrocement blocks which improves its properties are: Cement, Fine
Aggregate in the form of M sand (sand passing IS sieve 4.75mm and retaining on 150microns sieve) steel fibers and
steel mesh.
2. Cement:
Cement is the binding material that sets and hardens after Hydration. It becomes adhesive when in contact with
water. Cement used should be free from impurities and should not have any lumps. Zuari OPC 43 grade Cement is
used according to codal provision of IS8112:2013.
Tests on cement:
1. Specific gravity of cement
2. Normal consistency: The codal provision followed for Normal consistency is IS4031(Part4): 1988
3. Setting time: The codal provision followed for Setting time is IS4031(Part5): 1988
MATERIALS
Cement Properties Values obtained
1.Specific Gravity 3.15
2. Normal consistency 28%
3. Initial Setting time 70 min
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 8

9. 1. M- Sand: The M-sand of size passing IS sieve 4.75mm and retaining on sieve 150microns is used for preparation
of matrix in steel fiber reinforced ferrocement blocks. The sand used should be clean, free from impurities and should
be available locally. Tests on sand are shown as follows :
1. Specific gravity of fine aggregates
2. Sieve analysis
2. Steel Mesh: Mesh is as important as cement and aggregate, the properties of ferrocement blocks also depends on
type of mesh.
Here the steel mesh is used in ferrocement blocks because of its flexibility. Steel mesh is made up of galvanized steel
wire with hexagonal shaped gaps.
Wire diameter = 0.63mm.
Size of mesh opening = 10mm
Yield Strength of mesh=360-390 MPa.
Modulus of elasticity= 75-135 GPa.
Properties of M- sand Obtained value
Fineness modulus 2.58
Specific gravity 2.7
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 9

10. Various Percentages of steel fibers added
by weight of matrix
Steel Fibers added to mortar in gms
0.5% 314
1.0% 628
1.5% 942
3. Steel fibers: Steel fibers are well known for their ability to transfer stresses at very small cracks widths, so that the
ductility and post cracks strength will be provided to the matrix. Unlike traditional reinforcement, steel fibers are a
discontinuous and 3-dimensional oriented reinforcement, once it is mixed into the matrix.
The length to diameter aspect ratio it is the ratio between the length and diameter and steel mesh is used.
Aspect ratio = L/d
= 30/0.63
= 48
Tensile strength = >1100Mpa
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 10

11. Methodology is the flow of work, in order to cast the steel fiber reinforced ferrocement blocks from choice of materials to casting
and curing of the blocks. The work flow of blocks starts with :
1.Selection of materials.
2.Characterization of Materials
3. Selection of Mould size.
4. Mix proportions.
5. Casting and curing of Blocks. 1. Selection of Materials
The M-sand of size in between 4.75-150microns as fine aggregate is used. mesh is used instead of other types of mesh is
because of its flexibility. Steel fibers of aspect ratio (length/diameter = 30/0.63) of 48 are used.
2. Selection of mould size
The dimension of moulds is 230mmx190mmx90mm. The moulds used for casting blocks is made up of cast iron, during the
compaction it holds the matrix intact and easy to demould. Total 8 moulds are used in casting of the blocks.
3. Characterization Of materials
The materials so obtained were tested for Preliminary tests to find out the suitability and to check its standards as per the Indian
standard codes.
METHODOLOGY
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 11

12. STEEL FIBER's
MORTAR (matrix)
5. Casting of Blocks
SECTIONAL VIEW OF A FERROCEMENT BLOCK
The steps involved in casting of steel fiber reinforced ferrocement blocks are as follows:
• Overall length of block is measured and a thin firm base is provided as the mould is open.
• Layers of chicken meshes are laid at a distance of 30mm and 60mm each with alternate layers of matrix.
• Moulds are oiled or applied with grease before casting.
• The mix proportion of 1:3, without steel fibers are casted and w/c ratio 0.60, selected from trials of Flow table
test. The mix is then poured into mould of 230x190x90 mm and compacted.
• The mix proportion of 1:3, 0.5%, 1.0%, 1,5% steel fibers with aspect ratio (length/diameter = 30/0.63) of 48 is
taken and w/c ratio 0.60 is selected from trials.
30mm
30mm
4. Mix Proportion
The mix proportions are based on trial method. The combination of different ratios of cement M-sand and water
are tried and 1:3 proportion ratio yields better strength and workability ,that ratio of cement, sand and water is
adopted. The selection of water-cement ratio for the above ratio depends on strength and workability.
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 12

13. FIG: MIXING THE MATERIALS FOR REQUIRED PROPORTION FIG: CASTING OF THE BLOCKS
FIG: AFTER CASTING THE BLOCKS FIG: CURING OF THE BLOCKS6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 13

14. The blocks are tested for to evaluate the following properties:
• Dimensional Analysis
• Water Absorption
• Compressive Strength
• Flexural Strength
• Prism Strength in Compression
1. Dimensional Analysis
In Dimensional analysis, the number of blocks were placed length wise, the total length of that blocks arranged was
measured and average of that was taken. Similarly, the number of blocks were arranged breadth/width wise ,the total
width of arranged blocks were measured and the average is taken. This test was done to know the uniformity of the
size and shape of the blocks. The dimensional analysis was carried out as per code IS 1077 – 1976.
EXPERIMENTAL INVESTIGATION
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 14

15. 2. Water absorption
In water absorption test the casted blocks were immersed in water for about a period of about 24hrs and the rate of
water absorption was observed which should not exceed 20% of the total weight. The water absorption capacity test
was done to determine the effective porosity of concrete. Therefore, the increase in weight of a dry specimen when
immersed in a shallow depth of water is generally referred to as the water absorption capacity.
Fig: Water absorption test
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 15

16. 3. Compression Strength
Compression Strength on blocks of size 230x190x90mm
The masonry is generally subjected to compressive loading, so the steel fiber reinforced Ferrocement blocks were tested for
compressive strength in compression testing machine (CTM). The Compressive strength was carried out as per code IS 4031(Part
6) :1988
Compressive strength of blocks depends upon method of manufacturing (type of materials used, mix proportion, curing) and rate
of loading. Cubes of size 70.2x70.2x70.2mm were also tested for compression at 7 days and 28 days.
Fig: Compression Test on cubes
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 16

17. .
4. Flexural strength
Two point loading was used for the blocks of size 230x190x90mm and it was preferred because the mid span of block
is subjected to pure bending. Then using pure bending equation the flexural strength was found out. In two point
loading the block was divided into 3 parts and the load was applied at two points at a distance of L/3 .While in the
case of block i.e two point loading L/3 distance was marked, also a center line was drawn for the block.
P
SPECIMEN
LOADING PIN
SUPPORTING PINS
FORCE
Fig : 2 POINT LOADING TEST
L
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 17

18. Fig : Flexural test on Bricks and Blocks6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 18

19. 5. Prism strength in compression
A masonry prism is an assemblage of masonry units and mortar that is constructed to serve as a
test specimen for determining properties of masonry assemblages. The Bureau of Indian
Standards (IS:1905-1987)suggests testing of masonry prisms of minimum 40cm high with
height/thickness (h/t) ratio between 2 and 5 for determining the compressive strength of the
masonry. Prisms of size 230x190x90mm was incorporated in this investigation. An average
mortar joint of thickness of 10 mm was maintained in all the prism specimens and it was cured for
a period of 7 days and the bonded specimens were tested in a Universal Testing Machine. The
strength results obtained are represented in terms of the masonry efficiency, as per the guidelines
of IS:1905-1987.
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 19

20. Fig: Prism test on Bricks and Ferrocement Blocks6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 20

21. Tests on M-Sand
1.Test for specific gravity of M-sand
Empty weight of Pycnometer (W1)= 576gms
Weight of container + 1/3 of sand (W2)= 830gms
Weight of Pycnometer bottle+ Sand + Water (W3)=1624gms
Weight of Water + Pycnometer bottle (W4) = 1464gms
Formula is given by,
G= (W2- W1)
((W4 –W1)-(W3 - W2))
= 830-576/(1464-576)-(1624-830)
= 254/(888)-(794)G = 2.7
TESTS RESULTS:
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 21

22. 2. Fineness modulus of the M-sand
Sieve size
mm
Wt of
sand
retained
gms
Percentage
retained %
Cumulative
percentage
retained on each
sieve
Percentage finer
4.75 2 0.2 0.2 99.8
1512.36
1.18 135 13.5 28.8 71.2
300 200 20.0 71.3 28.7
600
150
225
206
15.1 15.3 84.7
22.5 51.3 48.7
20.6 91.9 8.10
Total=258.8
Fineness modulus of M-sand =258.8/100=2.58
Based on the results
obtained after conducting
fineness modulus ,the so
obtained results are
compared with the Indian
Standard Zoning table .
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 22

23. 600 micron meter
300 micron meter
150 micron meter
.
By the IS standard Zoning table , the M-sand used for Casting blocks falls under the Zone-1.
100
90-100
75-100
55-90
35-59
8-30
0-10
100
90-100
85-100
75-100
60-79
12-40
0-10
IS Sieve destination
Grading limits for M-sand as per (IS:383-1970) for the zoning of the sand
3. Zoning test for M-sand
:
Fineness modulus 4.0-2.71 3.37-2.10 2.78-1.71 2.25-1.35
100
90-100
75-100
55-100
35-59
8-30
0-10
100
95-100
95-100
90-100
80-100
15-50
0-15
Zone1 Zone 2 Zone4
Percentage passing by weight
Grading
Zone3
10mm
4.75mm
2.36mm
1.18mm
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 23

24. Tests on Cement
1.Specific gravity of cement
1.Empty weight of bottle(w1)=45gms
2.Weight of bottle + weight of cement(w2)=86gms
3.Weight of bottle + weight of kerosene added + weight of cement(w3)=146gms
4.Weight of bottle + water filled in bottle(w4)=136gms
Specific gravity G is given by, G=(W2-W1)/ (W2-W1)-(W3-W4)X0.79
G=(86-45)/(86-45)-(146-118)X0.79
G=3.15
Fig: Specific gravity of Cement
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 24

25. 2. Normal consistency of cement
Weight of cement taken = 300gms
Trials Percentage
of water
Water in
(ml)
Initial
reading
Final
reading
Penetration
(mm)
1 26 78 41 38 3
2 27 81 41 39 4
3 28 84 41 36 5
4 30 90 41 35 6
5 31 93 41 34 7
FIG: NORMAL CONSISTENCY TEST
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 25

26. 3. Initial setting time
Weight of cement = 300gms
Weight of water taken = (0.85*(31/100)*300)
= 79ml
Time(min) Initial reading Final reading Penetration(mm)
5 0 0 0
10 0 0 0
15 0 0 0
20 0 0 0
25 0 0 0
30 0 0 0
40 0 0 0
50 0 0 0
60 0 4 4
70 0 6 6
Initial setting time of cement is 70min .
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 26

27. Flow Table test:
The selection of water-cement ratio for the selected ratio depends on strength and workability:
The Flow value of mortar is determined as per IS 2240-1981,and steps involved are:
• The flow value was determined by using the Flow table equipment.
• The Flow table equipment consists of a mini slump cone of height 35mm,top diameter
78mm and bottom diameter 100mm.
• The matrix was mixed manually with 1:3 proportion and different w/c ratios (0.6,0.65,0.7).
• The mini cone was then transferred on to a table vibrator.
• In the mini cone the matrix was filled in 2 layers, each layer is tamped with 25 blows.
• Slump cone was filled completely and the surplus matrix was cleaned.
• Slump cone was lifted slowly without disturbing the matrix then table is allowed to jerk with
25 blows for about 15 secs (i.e it is allowed to go up and down for 25 times in 15 seconds).
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 27

28. FIG1: PROPORTIONING FOR THE TRIALS FIG2: FILLING THE FLOW TABLE MOULD FIG3: AFTER REMOVAL OF MOULD
FIG4: GIVING 25 NO OF JERK’s(JOLTING) FIG5: AFTER THE TEST FIG6: MEASURING THE SPREAD6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 28

29. w/c ratio Percentage spreading
Without fibers With fibers
0.5% 1.0% 1.5%
0.60 130.76 105.12 79.00 67.00
0.65 131.18 110.48 85.80 92.00
0.70 174.35 130.76 111.53 137.00
Combined table of both with and without fibers of flow table test
For mix proportion of 1:3 with 0.50 w/c ratio
Initial reading = 78mm
Final reading = 165mm
Therefore, flow percentage = (FR-IR)/IR X 100
= ((165-78) / 78) x100
= 111.53
From the Flow table test, we have taken the water cement ratio as 0.60 with the proportion
of 1:36/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 29

30. 1. Dimensional Test
Dimension Average length Average width Average Height
Block size of
230x190x90mm
235mm 192mm 92mm
Sample no. Weight of dry block
(W1), kg
Weight of wet
blocks (W2), kg
Percentage of
water absorbed %
1 8.322 8.560 2.88
2 8.350 8.50 1.79
3 8.290 8.590 3.61
2. Water Absorption Test
Water absorption is given by =
((W2 - W1)/ W1) x 100
Water absorption = ((8.560- 8.322)/
8.322) x 100 = 2.88%
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 30

31. COMPRESSION TEST ON CUBES
1: 6 cubes were casted and tested for plain cement matrix without the use of steel fibers. The codal
provision followed to determine compressive strength is IS3495 Part 1-1976.
Designation
of cube
Date of
casting
Date of testing Area mm2 Load
KN
Average Compressive
strength N/mm2
11/02 11/02/2019 18/02/2019 4928.04 13.70 13.80
11/02/2019 18/02/2019 4928.04 13.80
11/02/2019 18/02/2019 4928.04 13.92
11/02 11/02/2019 11/03/2019 4928.04 19.88 19.58
11/02/2019 11/03/2019 4928.04 19.27
11/02/2019 11/03/2019 4928.04 19.60
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 31

32. FIG: PLAIN MATRIX CUBES FIG: COMPRESSIVE STRENGTH TEST ON CUBE
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 32

33. 2: 6 cubes were casted and tested with addition of 0.5% fibers
Designation of
cube
Date of casting Date of testing Area mm2
Load KN Average
Compressive
strength N/mm2
A 15/02/2019 22/02/2019 4928.04 16.86 17.33
15/02/2019 22/02/2019 4928.04 17.48
15/02/2019 22/02/2019 4928.04 17.65
A 15/02/2019 15/03/2019 4928.04 24.75 24.68
15/02/2019 15/03/2019 4928.04 24.35
15/02/2019 15/03/2019 4928.04 24.95
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 33

34. 3: 6 cubes were casted and tested with addition of 1.0% fibers
Designation of
cube
Date of casting Date of testing Area mm2
Load KN Compressive
strength N/mm2
B 16/02/2019 23/02/2019 4928.04 21.69 21.36
16/02/2019 23/02/2019 4928.04 21.10
16/02/2019 23/02/2019 4928.04 21.30
B 16/02/2019 16/03/2019 4928.04 26.37 27.45
16/02/2019 16/03/2019 4928.04 27.59
16/02/2019 16/03/2019 4928.04 28.40
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 34

35. 4: 6 cubes were casted and tested with addition of 1.5% fibers
Designation of
cube
Date of casting Date of testing Area (mm2) Load KN Compressive
strength N/mm2
C 18/02/2019 25/02/2019 4928.04 23.53 23.73
18/02/2019 25/02/2019 4928.04 23.94
18/02/2019 25/02/2019 4928.04 23.74
C 18/02/2019 18/03/2019 4928.04 31.44 31.85
18/02/2019 18/03/2019 4928.04 31.85
18/02/2019 18/03/2019 4928.04 32.26
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 35

36. Description Area mm2 Load KN Compressive
strength N/mm2
Avg
Compressive
strength N/mm2
Plain Blocks 43700 1097 25.10 24.14
43700 1050 24.00
43700 1020 23.34
Blocks were
tested with
mesh
43700 1687 38.61 39.95
43700 1755 40.18
43700 1795 41.08
Blocks were
tested with
0.50% steel
fibers
43700 1863 42.65 43.24
43700 1912 43.77
43700 1893 43.32
Blocks were
tested with
1.0% steel
fibers
43700 2000 45.76 46.32
43700 2045 46.76
43700 2030 46.45
Blocks with
1.5% fibers
43700 2100 48.05 47.86
43700 2085 47.71
COMPRESSION TEST ON BLOCKS
Blocks were casted and tested with matrix and fibers
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 36

37. FLEXURAL STRENGTH
(i) Flexural strength values on Ferrocement Blocks
Sl No Description Load
KN
Flexural
strength of
blocks
N/mm2
Avg Flexural
strength N/mm2
1 Plain blocks 30 8.79 8.33
2 28 8.20
3 26 8.00
1 Mesh reinforced
Ferrocement blocks
33.78 9.78 10.32
2 36.00 10.5
3 36.60 10.7
1 Fiber reinforced
Ferrocement blocks
with 0.5% fibers
38.44 11.14 11.36
2 39.50 11.58
1 Fiber reinforced
Ferrocement blocks
with 1.0% fibers
44 12.80 12.60
2 42 12.31
1 Fiber reinforced
Ferrocement blocks
with 1..5% fibers
58.50 17.15 17.37
2 60.00 17.59
Flexural strength =3PL/2BD2
=3x30000x190/2x120x(90)2
= 8.79 N/mm2
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 37

38. (ii) Flexural strength of bricks
SI NO Load KN Flexural
strength
of bricks
N/mm2
Avg strength N/mm2
1 1.16 0.73
0.816
2 1.52 0.96
3 1.28 0.81
4 1.58 0.86
5 1.32 0.83
6 1.10 0.70
0
2
4
6
8
10
12
14
Category 1 Category 2 Category 3 Category 4
Flexural strength of Blocks and Bricks
Series 1 Series 3
6/30/2019 DEPT OF CIVIL ENGG, VEMANA IT 38

39. PRISM TEST IN COMPRESSION
Sl NO Dimension of
prism mm
Load KN Compressive
strength
N/mm2
Avg
compressive
strength
N/mm2
1 230x190x480 400 9.15
92 230x190x490 398 9.10
3 230x190x485 400 9.15
1. Prism test on Block Masonry
2. Prism strength on brick masonry
Sl No Dimension of
prism mm
Load KN Compressive
strength
N/mm2
Avg
compressive
strength
N/mm2
1 210x95x65 36.64 1.85
1.88
2 210x95x65 37.00 1.89
3 210x95x65 38.64 1.90
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40. 1. Cost of a Plain Ferrocement Block:
Size of block-230X190X90 mm
Cement-Rs 6 for 1.75kg
Sand-Rs 3 for 5.25kg
Mesh-Rs 3 for 0.47ft2
Therefore, Total cost for 1 block=Rs 12
Providing and constructing ferrocement block masonry with CM 1:4
Size of the block – 230 x 190 x 90 mm
Assume, quantity = 10 m3
Material calculation:
Quantity of block = 80% of 10 m3 (assume)
= 8 m3
Quantity of mortar = 20% of 10m3 = 2 m3.
Therefore, total blocks required =8/(0.23*0.19*0.09 ) = 2034 nos.
Quantity of wet CM = 2 m3. Add 30% more as shrinkage allowance
Dry volume of CM = 2.6 m3.
.
COST ANALYSIS
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41. Proportion of CM 1:4:-
Quantity of cement = 2.6/5*1= 0.52 m3.
1 m3 = 30 bags,
Therefore number of bags required = 0.52 * 30 = 16 bags.
Quantity of sand = 2.6/5*4= 2.08 m3.
For 10 m3 – Rs. 60805
1 m3 – Rs. 6080.5
Therefore for m3 cost is around = 6100 rupees
Therefore the cost of Brick masonry per m3 is around Rs 6100, but brick masonry is around Rs 7000
Particulars Quantity Rates Amount (rs)
Cement 16 bags Rs. 330/bag 6240
Sand 2.08 m3 3500/ m3 7280
Blocks 2034 Nos. Rs. 12/
block
24408
Total – 1 37928
Extra for
labour, curing,
scaffolding
etc.
25% of Total – 1
(approximated)
9500
Transportation
charges
2% 950
Total - 2 48378
Taxes 14.5% on Total – 2
(approximated)
6900
Total - 3 55278
Contractor
profit
10% of Total - 3 5527.8
Total - 4 60805
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42. 1. Flexural strength of Brick and Block:
The block with 1mesh layer was tested and were found that as the layers increased, the flexural strength of block also
increased. The below table shows the test on blocks with one layer mesh.
Sl.n
o
Load KN Flexural strength of
block N/mm2
Average Flexural
strength N/mm2
1 33.78 9.78 10.32
2 36.00 10.5
3 36.60 10.7
Similarly, the flexural test was conducted on bricks as per IS 1905-1987 also which we already know has a very less flexural
strength, it is as follows: Sl.
No.
Loads KN Flexural strength
of brick
N/mm2
Average Strength
N/mm2
1 1.16 0.73
0.816
2 1.52 0.96
3 1.28 0.81
4 1.58 0.86
5 1.32 0.83
6 1.10 0.70
From above tables we can conclude that the brick has very less flexural strength and as the numbers of mesh layers are increased
the flexural strength may keep increasing up to some extent. Since the flexural strength increases the blocks can be used in
earthquake prone areas
RESULTS, COMPARISONS AND DISCUSSIONS
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43. Brick Ferrocement block with
mesh
Dimension (mm) 220 X 105 X 70 230 X190 X 90
Material required Soil with clay as major constituent Cement, M-sand, Water
Cost (per m3 with CM
1:3)
7000 rupees 6100 rupees
Compressive strength 7 N/mm2 40.81 N/mm2
Flexural strength 0.816 N/mm2 10.32 N/mm2
Prism strength 1.8 N/mm2 with 1:6 mortar
joints
15 N/mm2 with 1:6 mortar
joints
Comparison between brick and block
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44. CONCLUSION
There are many blocks available in the market and many of them need sand/soil for its manufacturing whereas Ferrocement block
is a very unique kind of masonry block which possess all functional requirement to be used as a masonry block as well as an
alternative to the bricks. Since it doesn’t use natural sand or natural soil for its manufacturing it is eco-friendly to some extent. Its
nature is to increase in flexural strength by increasing number of layers of mesh or due to its increased flexural strength compared
to the brick it can be applied to build an earthquake resistant structure.
The performance of ferrocement blocks in compressive strength, flexural strength are far superior to Table moulded bricks. The
block has a compressive strength of 45N/mm2 & flexural strength of 11.68N/mm2, Brick has a compressive strength of 10N/mm2
& Flexural strength of 0.816N/mm2. Materials are locally available and cost per m3 is less than brick, the ferrocement block has a
good advantage to be used as a masonry block and be used as an alternative to the brick.
CONCLUSION
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45. Future scope:
 Matrix of other proportions like 1:5, 1:6, 1:7, 1:8 may be used for casting the blocks.
 Use of manufactured light weight aggregate may be considered.
 Pore filler like metakaoline may be incorporated to decrease permeability of blocks.
 Mode of compaction can be improved by designing a suitable mechanism.
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46. 1.Randhir J. Phalke, Darshan G. Gaidhankar, “ Flexural behaviour of ferrocement slab panels using welded square
mesh by incorporating steel fibers.”IJRET: International Journal of Research in Engineering and Technology.
2.Sri. Naveen G.M, Sri. G.S. Suresh, “EXPERIMENTAL STUDY ON THE DUCTILE CHARACTERISTICS OF
LIGHT WEIGHT FERROCEMENT BEAMS UNDER MONOTONIC AND REPEATED LOADING”. International
Journal of Innovative Research in Science, Engineering and Technology (An ISO 3297: 2007 Certified Organization)
3. Md Ihtesham Hussain, Vaijanath Halhalli, P.M.B Raj Kiran Nanduri, “SHEAR AND FLEXURAL BEHAVIOR
OF FERRO CEMENT DEEP BEAMS”. IJRET: International Journal of Research in Engineering and Technology
4.Yousry B.I. Shaheen, Noha M. Solima and Ashwaq M. Hafiz, “STRUCTURAL BEHAVIOUR OF
FERROCEMENT CHANNELS BEAMS”.
5.Manoj Kumar H R, Chakrapani B M and Kishora D S, “Behaviour of Fiber Reinforced Ferrocement Beams
Subjected Under Monotonic and Repeated Loading”.
REFERENCES
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47. THANK YOU
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