This paper presents the results of an investigation aimed at developing reinforced concrete beams consisting of precast permanent U-shaped reinforced mortar forms filled with different types of core materials to be used as a viable alternative to the conventional reinforced concrete beam. To accomplish this objective, an experimental program was conducted and theoretical model was adopted. The experimental program comprised casting and testing of thirty beams of total dimensions 300 × 150 × 2,000 mm consisting of permanent precast U-shaped reinforced mortar forms of thickness 25 mm filled with the core material. Three additional typical reinforced concrete beams of the same total dimensions were also cast to serve as control specimens. Two types of single-layer and double-layers steel meshes were used to reinforce the permanent U-shaped forms; namely welded wire mesh and X8 expanded steel mesh. Three types of core materials were investigated: conventional concrete, autoclaved aerated lightweight concrete brick, and recycled concrete. Two types of shear connections between the precast permanent reinforced mortar form and the core material were investigated namely; adhesive bonding layer between the two surfaces, and mechanical shear connectors. The test specimens were tested as simple beams under three-point loadings on a span of 1,800 mm. The behavior of the beams incorporating the permanent forms was compared to that of the control beams. The experimental results showed that better crack resistance, high serviceability and ultimate loads, and good energy absorption could be achieved by using the proposed beams which verifies the validity of using the proposed system. The theoretical results compared well with the experimental ones.

In this study, 10 ferroconcrete concrete (FC) beams with lightweight cores reinforced with welded steel mesh as a shear reinforcement were evaluated under three-point bending tests along with two conventionally normal-weight concrete (NWC) beams. Expanded polystyrene and lightweight aerated autoclaved brick wastes were used to create lightweight core concrete. The main factors include the type of lightweight concrete used for the core, beam concrete type, the form and number of holes, the existing steel mesh fabric, the hollow, and the hole placement. This study was done on the tested beams' ductility index, failure modes, first cracking loads and associated deflections, and ultimate loads besides corresponding deflections. Experimental results showed that the use of FC, various filling materials, and welded steel meshes in place of traditional stirrups enhanced the ultimate load by 36.6–107.3%, the ultimate deflection by 6–272%, and the ductility by 89–1155% when referenced to a control NWC beam. When the holing ratio increased from 10 to 20%, the ductility of FC beams was enhanced by 307.7%. Proposed equations were developed to predict the ultimate load and bending moment capacity of FC beams while taking into account the compressive strength of the beam body and filling material, the holing ratio, the tensile reinforcement ratio, and the volume fraction of the steel mesh.

This paper presents the results of a research work to develop ferrocement sandwich and hollow core panels for use as precast one way slab elements. Sandwich panels consisted of two thin ferrocement layers reinforced with steel wire mesh and a core of autoclaved aerated lightweight concrete bricks. The hollow core panels are made of the same ferrocement mortar matrix with three circular holes of 75 mm diameter running along the length of the specimen. A total of 15 sandwich panels and 12 hollow core panels were cast and tested under flexural loadings. The experimental results showed that high ultimate and service loads, crack resistance control, high ductility, and good energy absorption could be achieved by using the proposed panels. A theoretical model based on the ultimate strength method for reinforced concrete was developed to determine the ultimate moment and mode of failure of the panels. The theoretical and experimental results showed good agreement.