Muhuni Alex Macharia

85 Pages·2015·6.77 MB·English

UNIVERSITY OF NAIROBI

INVESTIGATING THE EXTENT OF USE OF FERROCEMENT
AS AN ALTERNATIVE BUILDING MATERIAL IN KENYA.

By Muhuni Alex Macharia, F16/35926/2010

This project was submitted as a partial fulfillment for the
requirement for the award of the degree of

BACHELOR OF SCIENCE IN CIVIL ENGINEERING

2015

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Abstract

Ferrocement construction technology is not well known throughout the world. Ferrocement, a
thin element, is used as a building construction as well as a repair material. This study is
intended to provide the reader with a sound basic knowledge of ferrocement and its potential and
limitations in construction. It is assumed that those people using this document are already
familiar with the construction using RCC. This study attempts to investigate the extent of use of
the ferrocement in Kenya’s Construction industry as well as review the literature on ferrocement
and bring out the salient features of construction, material properties and the special techniques
of applying cement mortar on to the reinforcing mesh. This study brings out the importance of
using ferrocement as an alternative building material to Reinforced Concrete (RCC), and also in
the repair of old/ deteriorated RCC structures. Also discussed and done is this paper is the
possibility of building structural components using ferrocement, waffles slabs and hollow poles
are used as examples. The waffle slabs are constructed using fabricated formwork and cast with
the appropriate mortar standards. The behaviour of the ferrocement waffle slab panels under
flexural loading is studied thus investigating the strength properties of the material. The study
also employs a field work survey and questionnaire to investigate the extent of use and
knowledge of ferrocement in Kenya. The field study revealed lack of knowledge of ferrocement
in Kenya. The recommendations of this study include addition of fibers in ferrocement to reduce
crack-width. The researcher recommends that experimental investigations may be conducted on
new reinforcing materials by researchers in the future. The study concludes that ferrocement will
certainly be one of the best structural alternatives for RCC in the future. This study is considered
preliminary and should be continually brought up to date as new advances are made in the
technology of ferrocement. Most developing countries are faced with problems of poverty, low
standards of living, environmental degradation and housing shortage. Ferrocement technology is
seen as an environmentally friendly low cost technology as seen in the recommendations herein
and should be extensively advertised as an alternative building material in Kenya.

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Dedication

To my parents: Patrick M Muhuni (OGW) and Joyce Sikuzani Mugo who took me to school.
There is no doubt in my mind that without their continued support and counsel I could not have
completed this process. They have helped me build both my personal and interpersonal skills.

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Acknowledgement

I would like to acknowledge the help and encouragement of my brother and mentor Martin
Sauka Muhuni a graduate Civil Engineer who has seen me through my studies not forgetting the
uncountable times we burnt the midnight oil together as I sought further understanding and
solutions on Engineering problems.

I would like to acknowledge the inspirational instructions and guidance of Eng. Wokabi (Mrs)
my project supervisor who has given me a deep appreciation and love for the beauty and detail of
this subject.

I would also like to acknowledge the support and assistance given me by the University Of
Nairobi Soils and Concrete Laboratory. They have been very generous in their support of my
academic pursuits allowing me to spend plenty of hours in the lab with continuous assistance
throughout this research.

Lastly I acknowledge my co-students who have contributed ideas, feedback and advice.

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Table of contents
Abstract .......................................................................................................................................... ii
Dedication ..................................................................................................................................... iii
Acknoledgement ........................................................................................................................... iv

Chapter One 1.0 Introduction ......................................................................................................1
1.1 Background of the problem………………………………………………………….. 1
1.2 Problem statement………………………...……………………………………….…………….3
1.3 Justification of the study………………………………………………………..…………….....4
1.4 Objectives…………………………………………………………………………......4
1.5 Scope of the study………………………………………………………………………5
1.6 Limitations of the study………………………………………………………………..5

Chapter Two 2.0 Literature review ..............................................................................................6

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2.1 Ferrocement definition……………………………………………………………….6
2.2 History of ferrocement……………………………………………………………….7
2.3 Constituents of ferrocement………………………………………………………….8
2.3.1 The matrix………………………………………………………………………….8
2.3.1.1 Cement……………………………………………………………………………8
2.3.1.2 Fine aggregates……………………………………………………………………8
2.3.1.3 Admixtures……………………………………………………………………….9
2.3.1.4 Reinforcement……………………………………………………………………9
2.3.1.5 Wiremesh…………………………………………………………………………9
2.4 Advantages of ferrocement…………………………………………………………..10
2.5 Substitute materials ………………………………………………………………….10
2.6 Other materials (water, coating) ……………………………………………………11
2.7 Tensile behaviour of Ferrocement ………………………………………………….12
2.8 Compressive strength of Ferrocement ……………………………………………..13
2.9 Flexural Strength…………………………………………………………………….13
2.10 Shear Strength………………………………………………………………………14
2.11 Fatigue resistance………………………………………………………………….14
2.12 Impact resistance……………………………………………………………………15
2.13 Fire resistance………………………………………………………………………15
2.14 Durability…………………………………………………………………………..15
2.15 Corrosion………………………………………………………………………….16
2.16 Construction procedure……………………………………………………………17
2.16.1 Design of Cement Mortar Matrix……………………………………………….18
2.16.2 Mortar Placement/ Application………………………………………………….19
2.16.3 Curing…………………………………………………………………………….20
2.17 Application of ferrocement………………………………………………………..20
2.17.1 Housing applications…………………………………………………………….20
2.17.2 Marine applications………………………………………………………………21
2.17.3 Agriculture applications…………………………………………………………23
2.17.4 Water and Sanitation applications………………………………………………..23
2.18 Conclusion from the literature……………………………………………………...25

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Chapter Three 3.0 Research methodology ................................................................................26

3.1 General Methodology Overview……………………………………………………..26
3.1.1 Qualitative approach in the research methodology………………………………...27
3.1.1.1 Reconnaissance study……………………………………………………………27
3.1.1.2 Questionnaire……………………………………………………………………27
3.1.2 Quantitative approach in the research methodology……………………………..27
3.2 Construction of structural components using ferrocement………………………….28
3.2.1 Preparation of materials…………………………………………………………..28
3.2.2 Preliminary Tests………………………………………………………………….28
3.2.2.1 Sieve analysis grading test on the sand used……………………………………28
3.2.2.2 Cube crushing strength check on the mortar used ………………………………30
3.3 Casting the ferrocement waffle slab…………………………………………………30
3.3.1 Preparation of the mould (formwork)……………………………………………...30
3.3.2 Preparation of the ferrocement mortar…………………………………………….34
3.3.3 Oiling the mould…………………………………………………………………..35
3.4 Making of mortar cubes……………………………………………………………37
3.5 Flexural tests on the waffle slab…………………………………………………….39
3.6 Making of a hollow ferrocement pole/pipe…………………………………………40

Chapter Four 4.0 Interpretation and analysis of results ..........................................................41

4.1.1 Experimental results………………………………………………………………41
4.1.2 Sieve analysis results……………………………………………………………..41
4.1.3 Mortar cube compressive strength…………………………………………………43
4.1.4 Results from the cube crushing test tabulated below…………………………….44
4.1.5 Results on building structural components using ferrocement…………………….47
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4.1.5.1 Results on making a hollow ferrocement pipe…………………………………48
4.1.6 Results on making a ferrocement waffle slab panel……………………………..50
4.1.6.1 Flexural load testing on the waffles…………………………………………….51
4.2 Field study results……………………………………………………………………53
4.2.1 Sky hut waffles…………………………………………………………………….53
4.2.1.1 Construction method of the Sky Hut Waffles…………………………………….54
4.2.2 Respondents from questionairres…………………………………………………58

Chapter Five 5.0 Recommendations and conclusion ................................................................61

5.1 Conclusion of this Research………………………………………………………..61
5.2 Recommendations of this Study……………………………………………………..63

References .....................................................................................................................................66
Appendices ....................................................................................................................................66

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LIST OF TABLES PAGE

Table 1.1: Guideline on desirable sand grading………………………………………………9
Table 3.1 Sieve analysis template ………………………………………………………………29
Table 3.2 Sieve analysis Acceptance Criteria table…………..………………………………29
Table 3.3 Cube crushing strength template……………………………………………………30
Table 3.4 Collapse loads on the slabs template………………………………………………………...39
Table4.1 Soil sample masses…………………………………………………………………….41
Table 4.2 Particle size distribution……………………………………………………………..42
Table 4.3 7day compression test results……………………………………………………….44
Table 4.4 28day compression test results……………………………………………………...45
Table 4.5 IS Compressive strength values……………………………………………………..47
Table 4.6 Collapse loads on the waffle slab…………………………………………………………52

LIST OF FIGURES PAGE

Figure 1: Research methodology……………………………………………………………….26
Figure 2 A graph of mortar strength against age….…………………………………………46
Figure 3 Pie chart showing knowledge of Ferrocement in Kenya…………..……….…….60
Figure 4 Pie chart showing use of Ferrocement in Kenya…………………………………..60

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LIST OF PLATES PAGE

Plate 1.1: A ferrocement tank in Kibwezi,Kenya………………………………………………………7
Plate 1.2 Mesh types commonly used in ferrocement…………………………………………………..10
Plate 2.1 A typical ferrocement house in India………………………………………………………….21
Plate 2.2 A ferrocement boat under construction in Germany………………………………………..22
Plate 2.3 A typical ferrocement boat in Germany………………………………………………………22
Plate 2.4 Some of the ferrocement structures found in the UNIVERSITY OF TECHNOLOGY OF
MALAYSIA……………………………………………………………………………………………….....24
Plate 3.1 A & B Circular saw machine (Located at University of Nairobi Timber Laboratory)..30
Plate 3.2 Block board pieces to be assembled…………………………………………………………31
Plate 3.3 A & B Assemly of the timber pieces using nails and proffesional wood glue…………31
Plate 3.4 Proffesional wood glue and claw hammer………………………………………………….32
Plate 3.5 A & B Spaces between assembled mould that are to be filled with a mixture of sawdust
and glue…………………………………………………………………………………………………..…32
Plate 3.6 A Mixing of sawdust and glue……………………………………………………………..….33
Plate 3.6 B Filling of the spaces with the mixture…………………………………………………..…33
Plate 3.7 Final Product-mould with channel around it……………………………………………….33
Plate 3.8 Three parts of sand mixed with one part of cement………………………………………..34
Plate 3.9 Mortar ready for use in the casting of the ferrocement slab……………………………...34
Plate 3.10 A Oiling the mould…………………………………………………………………………....35
Plate 3.10 B Oiled mould…………………………………………………………………………………35
Plate 3.11 A Placing mortar on mould………………………………………………………………….36
Plate 3.11 B Cast waffle slab left to dry………………………………………………………………..36
Plate 3.12 A Demoulding of the waffle slab…………………………………………………………..36
Plate 3.12 B Demoulded waffle slab…………………………………………………………………….36
Plate 3.13 A Demoulded waffle slab…………………………………………………………………….36
Plate 3.13 B Slab left to cure under water…………………………………………………………….37
Plate 3.14 A Oiling the moulds………………………………………………………………………….38
Plate 3.14 B Assembling the moulds…………………………………………………………………….38
Plate 3.14 C Vibrating the mortar……………………………………………………………………….38
Plate 3.15 Mortar cubes left to cure before demoulding…………………………………………….40
Plate 3.16 A Folding the wire mesh…………………………………………………………………………..40
Plate 3.16 B Assembly and oiling of the mould……………………………………………………………….40
Plate 3.17 Pipe and mesh placed in the cylindrical mould…………………………………………………..40
Plate 3.18 Mortar placed in the spaces and well vibrated………………………………………………….40
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