Ultimate Guide To What Are The Pros And Cons Of A Concrete Slab ...

Welcome to our comprehensive guide on the pros and cons of a concrete slab foundation. Choosing the right foundation for your home is a crucial decision that impacts everything from construction costs to long-term maintenance and energy efficiency. In this article, we&#;ll delve into what makes concrete slab foundations a popular choice, exploring their advantages, such as cost-effectiveness, durability, and low maintenance, while also addressing potential drawbacks like cracking, repair difficulties, and thermal discomfort. Whether you&#;re planning a new build or considering foundation options for an existing structure, this guide will provide you with the insights needed to make an informed decision.

Read more

A concrete slab foundation is a cost-effective, durable, and low-maintenance option for home construction. It offers advantages such as resistance to pests, energy efficiency, and quick installation. However, it also has drawbacks, including the potential for cracking, difficulty in making repairs, and susceptibility to cold floors without proper insulation. Understanding these pros and cons can help homeowners decide if a concrete slab foundation is the right choice for their needs.

Understanding Concrete Slab Foundations

Concrete slab foundations are a popular choice for many buildings due to their durability and simplicity. Here&#;s an in-depth look at what they are, how they are constructed, and the different types available.

Definition

A concrete slab foundation is a flat, horizontal surface made of concrete, typically used as a base for building construction. This foundation type provides a solid and level support structure for buildings, helping distribute the weight evenly across the ground. Concrete slabs can vary in thickness, but they are generally between 4 to 6 inches thick, and reinforced with steel bars or mesh for added strength and stability.

Construction Process

The construction of a concrete slab foundation involves several crucial steps to ensure a strong and durable base. Here&#;s a detailed breakdown of the process:

Site Preparation

1. Clearing and Excavation: The first step is clearing the construction site of any vegetation, debris, and existing structures. This process also involves excavating the ground to the required depth, ensuring a level surface.

2. Soil Compaction: After excavation, the soil is compacted to provide a stable base. This step is critical to prevent settling and shifting that can lead to foundation cracks.

3. Formwork Installation: Wooden or metal forms are set up around the perimeter of the intended slab area. These forms act as molds that hold the concrete in place during pouring and curing.

4. Gravel and Vapor Barrier: A layer of gravel is spread within the forms to aid drainage and prevent moisture from seeping into the slab. Additionally, a vapor barrier, typically a plastic sheet, is placed over the gravel to further block moisture.

Pouring the Concrete

1. Mixing the Concrete: Concrete is mixed either on-site or delivered pre-mixed. The mixture usually consists of cement, sand, gravel, and water, with possible additives for specific properties like faster curing or increased strength.

2. Pouring: The mixed concrete is then poured into the prepared forms. It&#;s spread evenly and compacted using tools like shovels and rakes to remove air pockets and ensure a uniform surface.

3. Leveling and Smoothing: After pouring, the concrete surface is leveled and smoothed using a screed board and trowels. This step is vital for achieving a flat and even foundation.

Curing Process

1. Initial Setting: The concrete begins to set and harden within a few hours of pouring. During this time, it&#;s essential to keep the surface moist to prevent cracking.

2. Curing: Curing is the process of maintaining adequate moisture and temperature conditions for the concrete to achieve its full strength. This process can take anywhere from a few days to a few weeks, depending on the concrete mix and environmental conditions.

3. Final Hardening: After the curing period, the concrete slab reaches its full strength and hardness, ready to support the structure&#;s weight.

Types of Concrete Slab Foundations

There are several types of concrete slab foundations, each suited for different building needs and soil conditions. Here are two common types:

Monolithic Slabs

A monolithic slab is poured all at once, forming a single, continuous piece of concrete. This type of slab includes thickened edges that act as the foundation&#;s footing, providing additional support. Monolithic slabs are quicker and more cost-effective to construct, making them a popular choice for residential buildings.

Post-Tensioned Slabs

Post-tensioned slabs incorporate steel cables or tendons that are tensioned after the concrete has been poured and partially cured. This process increases the slab&#;s strength and allows it to span larger areas without the need for additional support beams. Post-tensioned slabs are often used in commercial buildings and structures with challenging soil conditions.

Understanding concrete slab foundations is crucial for anyone involved in construction or looking to build a new structure. These foundations offer a robust and reliable base, ensuring the longevity and stability of the building. By knowing the construction process and the types available, you can make informed decisions that best suit your project&#;s needs.

Advantages Of A Concrete Slab Foundation

Concrete slab foundations offer several benefits that make them an attractive option for many homeowners and builders. Here&#;s a comprehensive look at the advantages of opting for a concrete slab foundation:

Cost-Effective

One of the primary reasons many people choose a concrete slab foundation is its cost-effectiveness. Concrete slabs can be significantly less expensive than other foundation types, such as basements or crawl spaces. This cost advantage comes from several factors:

Reduced Excavation Costs: Unlike basements that require deep digging, concrete slabs need only shallow excavation, which reduces labor and machinery expenses.

Quicker Construction Time: Concrete slabs can be poured and set in a matter of days, speeding up the construction timeline. This efficiency translates to lower labor costs and allows homeowners to move into their new homes faster.

Durability and Strength

Concrete slab foundations are known for their exceptional durability and strength. Here&#;s why they stand out:

Robustness and Longevity: Concrete is an incredibly tough material that can withstand heavy loads and extreme weather conditions. A properly installed concrete slab can last for decades without significant issues.

Resistance to Pests: Unlike wood foundations, concrete slabs are impervious to termites and other pests that can cause severe structural damage. This resistance helps maintain the integrity of the foundation over time.

Energy Efficiency

Concrete slabs contribute to a home&#;s energy efficiency in several ways:

Thermal Mass: Concrete has excellent thermal mass properties, meaning it can absorb and store heat during the day and release it at night. This natural temperature regulation helps keep indoor temperatures stable, reducing the need for heating and cooling.

Reduced Air Infiltration: With no gaps or crawl spaces under the house, concrete slabs minimize air infiltration, keeping conditioned air inside and reducing energy costs.

Low Maintenance

Another significant advantage of concrete slab foundations is their low maintenance requirements. Here&#;s what makes them so easy to care for:

Minimal Repairs Needed: Concrete slabs are less likely to suffer from issues like rot, mold, or warping compared to wood foundations. This durability means fewer repairs and maintenance tasks over the years.

Simple Cleaning: The surface of a concrete slab is easy to clean and maintain, requiring only occasional sweeping and mopping to keep it in good condition.

Versatility

Concrete slab foundations offer remarkable versatility, making them suitable for various building styles and terrains:

Adaptable Design: Whether you&#;re building a modern home, a traditional ranch-style house, or anything in between, concrete slabs can be tailored to fit your architectural needs.

Suitable for Various Terrains: Concrete slabs can be poured on almost any type of terrain, including flat, sloped, or uneven ground. This adaptability makes them a viable option for many different building sites.

In conclusion, concrete slab foundations provide numerous advantages, from cost savings and durability to energy efficiency and low maintenance. Their versatility and robustness make them a smart choice for many construction projects, ensuring a solid foundation that stands the test of time.

Disadvantages Of A Concrete Slab Foundation

While concrete slab foundations offer many benefits, they come with their own set of drawbacks that homeowners should be aware of before making a decision.

Potential for Cracking

One of the primary concerns with concrete slab foundations is the potential for cracking. This issue often arises due to soil movement and temperature changes. When the soil beneath a slab expands or contracts, it can place stress on the concrete, leading to cracks. Additionally, temperature fluctuations can cause the concrete to expand and contract, which might result in further cracking.

To mitigate these risks, proper construction techniques and soil preparation are crucial. Ensuring that the soil is well-compacted and stable can help reduce the likelihood of movement. Moreover, using control joints in the slab can help manage where the cracks occur, minimizing their impact on the structural integrity of the foundation.

Difficulty in Repairs

Concrete slab foundations can pose significant challenges when it comes to repairs, particularly for plumbing and electrical systems located beneath the slab. Accessing these systems requires breaking through the concrete, which is both time-consuming and costly. For instance, if there is a plumbing leak under the slab, the concrete must be cut open, the issue fixed, and then the slab must be repaired and resurfaced. This process can be expensive and disruptive to the household.

Homeowners should consider these potential complications when choosing a slab foundation, as repair costs can add up quickly if issues arise. It&#;s important to weigh these potential repair challenges against the initial cost savings of a slab foundation.

Thermal Discomfort

Concrete can also contribute to thermal discomfort within a home. Without proper insulation, a concrete slab can feel cold underfoot, especially in cooler climates. This can lead to increased heating costs as homeowners attempt to maintain a comfortable indoor temperature.

One effective solution to this problem is the installation of radiant floor heating. This system involves embedding heating elements within the concrete slab, which can help keep the floor warm and provide a more consistent overall temperature in the home. While this adds to the initial construction cost, it can greatly enhance comfort and reduce long-term energy expenses.

Flood Risk

Homes built on concrete slab foundations are particularly vulnerable to flooding, especially in areas with high water tables or heavy rainfall. Since the slab is close to the ground, it can be easily affected by rising water levels, leading to water damage and potential mold growth.

To protect against this risk, it&#;s essential to ensure proper drainage around the home. This includes grading the landscape to direct water away from the foundation and installing appropriate drainage systems, such as French drains or sump pumps. Taking these preventative measures can help safeguard the home from flood damage.

Limited Crawl Space

Another disadvantage of concrete slab foundations is the lack of crawl space. Unlike homes with raised foundations, there is no space beneath the slab for additional storage or for housing mechanical systems like HVAC units.

This limitation means that any maintenance or repairs to these systems can be more challenging and intrusive. For instance, servicing ductwork or plumbing requires accessing it from inside the home rather than a crawl space, which can be more cumbersome.

In summary, while concrete slab foundations offer several advantages, they also come with significant disadvantages, including the potential for cracking, difficulty in repairs, thermal discomfort, flood risk, and limited crawl space. Homeowners should carefully consider these factors and consult with professionals to determine if a slab foundation is the best choice for their specific needs and circumstances.

Comparing Concrete Slab Foundations To Other Foundation Types

Concrete Slab vs. Basement

When comparing concrete slab foundations to basement foundations, several key factors come into play: cost, construction time, usability, climate suitability, and the potential for additional living space.

Cost

Concrete slab foundations are generally more cost-effective than basement foundations. The materials and labor required for a slab are less intensive, resulting in lower overall costs. Basements, on the other hand, involve significant excavation, waterproofing, and structural support, which can substantially increase expenses.

Construction Time

Construction time for concrete slabs is typically shorter. Since slabs involve pouring concrete directly onto a prepared surface, they can be completed relatively quickly. Basement foundations require more complex construction steps, including digging, forming walls, and ensuring proper drainage, all of which extend the timeline.

Usability

Basements offer additional usable space, which can be a significant advantage for homeowners looking for extra storage or living areas. They can be finished to include bedrooms, family rooms, or even home gyms. Concrete slabs, while simpler, do not offer this additional below-ground space, making them less versatile in terms of usability.

Climate Suitability

The choice between a slab and a basement can also depend on climate. In regions with high water tables or frequent flooding, basements may be prone to water infiltration, making slabs a more practical option. Conversely, in colder climates, basements provide better insulation against the cold, making them a preferable choice for energy efficiency and comfort.

Potential for Additional Living Space

Basements inherently offer more potential for additional living space compared to concrete slabs. This can be a major selling point for homes with basements, as they can be adapted for various uses over time. However, finishing a basement involves additional costs and time, which should be considered when evaluating overall benefits.

Concrete Slab vs. Crawl Space

When comparing concrete slabs to crawl space foundations, the discussion often revolves around maintenance, energy efficiency, pest control, accessibility for repairs, and moisture control.

Maintenance

Concrete slabs generally require less maintenance compared to crawl spaces. Since slabs are solid and have no voids underneath, there&#;s less risk of issues such as moisture buildup, pests, or structural damage over time. Crawl spaces, on the other hand, can be susceptible to these problems, necessitating regular inspections and maintenance.

Energy Efficiency

Concrete slabs can offer superior energy efficiency. Because they are in direct contact with the ground, they can help maintain stable indoor temperatures, reducing the need for heating and cooling. Crawl spaces, if not properly insulated and sealed, can allow air leakage, making it harder to regulate indoor temperatures efficiently.

Pest Control

Concrete slabs are generally better at preventing pest infestations. The solid nature of the slab leaves fewer entry points for pests like rodents or insects. Crawl spaces, with their open areas, can become a haven for pests unless properly managed and sealed.

Accessibility for Repairs

Crawl spaces provide easier access for repairs. Plumbing, electrical systems, and HVAC units are often routed through crawl spaces, making them more accessible for maintenance and repairs. In contrast, any issues with systems embedded in a concrete slab can be more challenging and costly to address.

Moisture Control

Moisture control is another crucial factor. Concrete slabs, if properly constructed with vapor barriers, are less prone to moisture issues. Crawl spaces, however, can be more vulnerable to moisture from the ground, which can lead to mold, mildew, and structural problems if not adequately managed. Proper ventilation and moisture barriers are essential to mitigate these risks in crawl spaces.

By understanding these differences, homeowners and builders can make more informed decisions about which foundation type best suits their needs, taking into account factors like cost, usability, maintenance, and environmental considerations.

Factors To Consider When Choosing A Foundation

When embarking on a construction project, one of the most critical decisions you&#;ll make is choosing the right foundation. This choice isn&#;t just about ensuring your building stands tall and strong; it also impacts your project&#;s budget, long-term maintenance, and future adaptability. Here are the key factors to consider:

Climate and Soil Conditions

The local climate and soil type play a pivotal role in determining the most suitable foundation for your building. 

Climate: If you&#;re in an area prone to heavy rainfall, flooding, or extreme temperatures, your foundation needs to be robust enough to withstand these conditions. For instance, areas with significant rainfall may benefit from deeper foundations or those with better drainage capabilities to prevent waterlogging and structural damage.

Xingtai Steel are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.

Soil Type: The type of soil on your site can greatly affect foundation performance. Sandy soils, for example, might require deeper foundations to reach stable ground, while clay soils can expand and contract with moisture changes, necessitating special consideration to avoid cracking and shifting. Conducting a soil test before deciding on your foundation type is essential to avoid future problems.

Building Type and Design

The architectural style and intended use of your building also influence foundation choice.

Concrete Slabs: Concrete slabs are a popular choice for many modern architectural styles. They provide a clean, level base and are especially suitable for single-story buildings and homes in warm climates. However, they might not be the best option for every design. For example, homes with basements or multi-story buildings may require deeper foundations such as piers or crawl spaces to provide adequate support and access to utilities.

Architectural Styles: Different architectural styles may also dictate the type of foundation. For instance, traditional homes with heavy masonry walls may require stronger, more reinforced foundations compared to lightweight, modern designs that might do well with simpler, slab foundations.

Budget and Long-Term Costs

Budget constraints are always a consideration, but it&#;s essential to look beyond the initial cost when choosing a foundation.

Initial Costs: While a concrete slab might be cheaper to install than a full basement, it&#;s important to consider what you&#;re getting for your money. Initial savings can sometimes lead to higher long-term costs if the chosen foundation is not suitable for the site conditions or building design.

Long-Term Maintenance and Repair: Think about the long-term implications. A foundation that is more expensive initially but requires minimal maintenance may be more cost-effective over the building&#;s life. For example, a slab foundation in a stable climate may need very little maintenance, whereas a pier foundation in an area with shifting soils might require regular inspections and repairs.

Future Proofing

Your building needs today might not be the same in the future. Consider how your foundation choice can accommodate potential changes.

Additional Space: If you plan to expand your building in the future, choose a foundation that can support additional structures. A slab foundation might limit your ability to add basements or additional floors later on.

Modifications: Consider whether your foundation can easily accommodate future modifications. For instance, if you foresee the need for new utility lines or significant renovations, a crawl space foundation offers more flexibility than a slab, which can be difficult and expensive to alter.

Choosing the right foundation is a complex decision that impacts the overall success and longevity of your building. By considering the local climate and soil conditions, the type and design of your building, your budget, and future needs, you can make an informed choice that ensures stability and cost-effectiveness for years to come.

Expert Opinions And Real-Life Examples

Interview with a Builder/Contractor

To gain a deeper understanding of the practical aspects of concrete slab foundations, we spoke with John Thompson, a seasoned builder with over 20 years of experience in the construction industry. John has worked on numerous projects involving concrete slab foundations and shared his insights on the benefits and challenges associated with this type of foundation.

Pros of Concrete Slab Foundations

1. Durability: According to John, concrete slab foundations are incredibly durable and can withstand a variety of environmental conditions. &#;A well-constructed slab can last for decades without major issues,&#; he says.

2. Cost-Effective: John highlights that concrete slabs are generally more cost-effective than other types of foundations. &#;They require less excavation and fewer materials, which can lead to significant savings.&#;

3. Pest Resistance: &#;Unlike wooden foundations, concrete slabs are impervious to termites and other pests,&#; John points out. This can be a crucial factor in areas prone to termite infestations.

4. Energy Efficiency: John explains that concrete slabs can help with energy efficiency. &#;The thermal mass of the concrete can help maintain a stable indoor temperature, reducing heating and cooling costs.&#;

Cons of Concrete Slab Foundations

1. Limited Access for Repairs: One of the main drawbacks, according to John, is the difficulty in accessing plumbing and electrical systems embedded in the slab. &#;If there&#;s a problem with these systems, it often requires breaking through the concrete, which can be costly and disruptive.&#;

2. Potential for Cracking: While durable, concrete slabs can develop cracks over time. John advises regular inspections and maintenance to address minor cracks before they become significant issues.

3. Initial Setup: &#;The initial curing process of the concrete requires time and proper conditions,&#; John notes. &#;It&#;s essential to ensure the concrete is properly cured to prevent future problems.&#;

Case Study

To illustrate the real-life application of concrete slab foundations, let&#;s look at the example of Sarah and Mark Thompson, homeowners in Wellington. They opted for a concrete slab foundation when building their new home three years ago.

Background

Sarah and Mark were attracted to the idea of a concrete slab foundation due to its affordability and low maintenance. &#;We wanted a foundation that would be durable and resistant to pests, as we&#;ve had issues with termites in the past,&#; Sarah explains.

Experience

Since moving into their home, Sarah and Mark have been pleased with their decision. &#;The house has stayed cool in the summer and warm in the winter, thanks to the thermal properties of the slab,&#; Mark notes. They&#;ve also appreciated the pest resistance, as they&#;ve had no issues with termites or other pests.

However, they did encounter a minor challenge when they decided to add a new bathroom. &#;We had to break through the slab to install new plumbing, which was a bit of a hassle,&#; Sarah recalls. Despite this, they still believe the benefits outweigh the drawbacks.

Overall, Sarah and Mark&#;s experience highlights the practical advantages of concrete slab foundations, while also acknowledging the potential challenges. Their story underscores the importance of considering both the pros and cons when choosing a foundation type for your home.

By including expert opinions and real-life examples, this section aims to provide a comprehensive and relatable perspective on concrete slab foundations, helping you make an informed decision for your construction project.

FAQs: About What Are The Pros And Cons Of A Concrete Slab Foundation?

What is a concrete slab foundation?

A concrete slab foundation is a flat, single-layer concrete base used as the foundation for a building. It is poured directly onto the ground, providing a stable and durable platform for construction.

What are the main advantages of a concrete slab foundation?

The main advantages include cost-effectiveness, durability, low maintenance, resistance to pests, energy efficiency, and quick installation. These benefits make it a popular choice for many homeowners.

What are the common disadvantages of a concrete slab foundation?

Common disadvantages include the potential for cracking, difficulty in making repairs to plumbing or electrical systems underneath the slab, thermal discomfort due to cold floors, and susceptibility to flooding in areas with high water tables.

How does a concrete slab foundation compare to a basement foundation?

Compared to a basement foundation, a concrete slab is generally less expensive and quicker to install. However, basements offer additional living or storage space and are better suited for areas with cold climates, as they provide better insulation.

Can a concrete slab foundation crack?

Yes, concrete slab foundations can crack due to soil movement, temperature changes, or improper construction. Proper site preparation, using quality materials, and following best practices in construction can help minimize the risk of cracking.

How is a concrete slab foundation constructed?

The construction process involves site preparation, including clearing and leveling the ground, followed by laying a base layer of gravel for drainage. Concrete is then poured and leveled, and the slab is allowed to cure, which strengthens the foundation.

Is a concrete slab foundation suitable for all types of homes?

Concrete slab foundations are versatile and can be used for various types of homes, particularly in warmer climates. However, they may not be ideal for areas with significant soil movement or for homeowners who want a basement or crawl space.

How does a concrete slab foundation impact energy efficiency?

Concrete slab foundations can contribute to energy efficiency by providing thermal mass, which helps maintain stable indoor temperatures. However, without proper insulation, the slab can feel cold, so additional measures like radiant floor heating might be necessary.

What maintenance is required for a concrete slab foundation?

Concrete slab foundations require minimal maintenance. Homeowners should ensure proper drainage around the foundation to prevent water accumulation and inspect for any cracks or signs of damage periodically. Prompt repair of any issues can prevent further problems.

How does soil type affect the suitability of a concrete slab foundation?

Soil type plays a significant role in the suitability of a concrete slab foundation. Stable, well-drained soils are ideal, while expansive soils that swell and shrink with moisture changes can pose challenges. Soil testing and proper site preparation are crucial to ensure a stable foundation.

Conclusion

In conclusion, this article has provided a comprehensive overview of the key aspects of choosing between a concrete slab and a timber floor foundation for your home in New Zealand. We&#;ve discussed the benefits and drawbacks of each option, including factors such as cost, durability, and suitability for different soil types. Ultimately, whether a concrete slab foundation is the right choice for you depends on your unique needs and circumstances. While concrete slabs offer excellent stability and resistance to pests, they might not be the best fit for all situations. It&#;s crucial to weigh these considerations carefully and consult with a professional builder or contractor who can provide personalized advice and help you make an informed decision that best suits your specific situation.

This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made. The images or other third party material in this article are included in the article's Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article's Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/

Recent and past studies mainly focus on reducing the dead weight of structure; therefore, they considered lightweight aggregate concrete (LWAC) which reduces the dead weight but also affects the strength parameters. Therefore, the current study aims to use varied steel wire meshes to investigate the effects of LWAC on mechanical properties. Three types of steel wire mesh are used such as hexagonal (chicken), welded square, and expanded metal mesh, in various layers and orientations in LWAC. Numerous mechanical characteristics were examined, including energy absorption (EA), compressive strength (CS), and flexural strength (FS). A total of ninety prisms and thirty-three cubes were made. For the FS test, forty-five 100 × 100 × 500 mm prism samples were poured, thirty-three 150 × 150 × 150 mm cube samples were made, and forty-five 400 × 300 × 75 mm EA specimens were costed for fourteen days of curing. The experimental findings demonstrate that the FS was enhanced by adding additional forces that spread the forces over the section. One layer of chicken, welded, and expanded metal mesh enhances the FS by 52.96%, 23.76%, and 22.2%, respectively. In comparison to the remaining layers, the FS in a single-layer hexagonal wire mesh has the maximum strength, 29.49 MPa. The hexagonal wire mesh with a single layer had the greatest CS, measuring 36.56 MPa. When all three types of meshes are combined, the CS does not vary in this way and is estimated to be 29.79 MPa. In the combination of three layers, the chicken and expanded wire mesh had the most energy recorded prior to final failure, which was .6 and .7 J, whereas it was found the highest 752.3 J for welded square wire mesh. The energy absorption for the first layer with hexagonal wire mesh increased by 82.81% prior to the crack and by 88.34% prior to the ultimate failure. Overall, it was determined and suggested that hexagonal wire mesh works better than expanded and welded wire meshes.

Several studies have been conducted using confinement behaviour in beams and columns at different angles and spacing to enhance the strength properties. Past researchers mostly focus on the utilization of waste materials as a natural aggregate replacement to reduce the use of natural resources, enhance strength parameters, and promote a green and sustainable environment. The latest studies in the concrete industry focus on the utilization of modern techniques such as AI and ML for the prediction of strength properties and claim that modern techniques outperformed conventional techniques. However, according to the author's view and past studies, there has been a limited study on ferrocement by using different layers of several wire meshes in LWA concrete to investigate the mechanical properties and energy absorption. Therefore, the current study aims to use varied steel wire meshes such as hexagonal (chicken), welded square, and expanded metal mesh in various layers and orientations to investigate the effects of LWAC on mechanical properties.

Moreover, latest studies used modern techniques such as artificial intelligence and machine learning techniques to study mechanical properties of concrete incorporating different wastes to enhance the model stability and efficiency. For instance, Nafees et al. 35 , studied the mechanical properties of silica fume-based green concrete using ML techniques. Asghar et al. 8 , compiled a review on the structural and mechanical performance of geopolymer concrete to promote green and sustainable construction. Moreover, LWAC is widely used in the construction industry by using several conventional and analytical tools. Room et al. 36 , studies the LWAC incorporating textile washing stone, whereas Ali et al. 37 , applied central composite design application using response surface methodology to study the strength properties of LWAC incorporating pumice stone.

Ferrocement has several advantages, including strength, durability, and versatility, but it also comes with challenges such as the need for skilled labor, quality control, and potential brittleness. Recent and past studies used cement mortar construction materials to study the strength parameters such as Lesovik et al. 30 , studies the mortar for 3D printing by mineral modifiers to improve the performance, while Barreto et al. 12 , used the clay ceramic as a pozzolan constituent in cement for structural concrete. Moreover, Alani et al. 31 , studied demolishing waste and used in concrete to completely replace the cement and develop cement-free binders. Murali et al. 32 , studied the crumb rubber as a aggregate replacement from 5 to 30% with 5% increment and concluded that it enhance the initial crack and failure impact energy absorption capacity. Recently, researchers studied the confinement methods at different angles and spacing to enhance the strength properties of concrete 33 . For instance, Ali et al. 34 , studies the confinement behaviour low strength concrete under axial compression using experimental and analytical approaches.

Ferrocement is generally cast by encapsulating the steel mesh with a properly designed cement mortar (made of cement and natural sand, with no coarse aggregate like gravel) in smaller thicknesses (ranging from 10 to 25 mm) which usually gives high strength due to the availability of reinforced wire mesh 27 . The construction of ferrocement structures requires specialized skills and expertise, particularly in terms of forming and applying the cement mortar and reinforcement. In Ferrcement, the cement matrix does not crack since cracking forces are taken over by wire mesh reinforcement immediately below the surface. However, corrosion is one of the primary concerns that must be addressed in order to improve the long-term service life of ferrocement composites 28 . After this, it is not surprising that the brittle nature of concrete is an inherent property of the material and one that is overcome using reinforcing materials. As stated by Prathima and Jaishankar 29 due to the close spacing interlocks of the steel meshes the reinforced concrete member provides good ductility and bearing capacity. Recent and past studies concluded that by providing an additional layer of wire mesh improves FS, EA, and cracking behaviour. A substantial number of longitudinal mesh wires allow for a bond transfer between the cement matrix and the reinforcing mesh, which improves toughness and impact resistance while also demonstrating good crack control 27 .

The material Ferrocement is defined as a material type of thin wall-reinforced concrete structure commonly constructed of hydraulic cement mortar reinforced by small-sized wire mesh as per the committee of American concrete institute 22 . It has a number of special qualities, benefits, and challenges. Ferrocement is the first and oldest form of reinforced concrete which was used in France and Italy for the construction of boats dating back two centuries 23 , 24 , whereas its use in building construction began in the middle of the twentieth century in Italy. Ferrocement laminates are used to improve the overall performance of constructions including composite bridge decks, beams, and bearing walls 5 , 25 , 26 . Although its application in a large number of fields has rapidly increased all over the world, the state-of-the-art of Ferro cement is still in its infancy, as its long-term performance is still unknown.

Despite the disadvantages of traditional concrete, there are some benefits of plain concrete. It's critical to keep a balanced viewpoint while debating the benefits and drawbacks of conventional materials such as plain concrete. Conventional concrete is the material of choice for many different construction applications because of its well-known strength and durability. One of its main advantages is that it can endure large loads and challenging weather. Conventional concrete is highly versatile, fire resistant, and has a low maintenance cost once properly installed. Corrosion of reinforced cement concrete structures takes place in the main reinforcement in the slab, beam, and stirrups, where cover is not provided well. To overcome such problems in the construction industry, Ferrocement, among other materials, has emerged. There are certain similarities and differences between reinforced concrete and ferrocement materials, indicating that ferrocement requires a separate investigation to determine its structural performance 21 .

Apart from the natural resources, plain concrete has several challenges such as low tensile strength, ductility, high porosity especially in severe service conditions, and resistance to crack propagation 10 . Recent and past studies took several approaches to improve concrete properties, resulting in quite different materials 11 &#; 15 . Serviceability criteria such as excessive crack width and deflection impair the appearance of the structure, weakening the member due to corrosion of steel and damaging non-structural members become more critical than the strength consideration 16 . Due to the technological development, recent studies focusing on the utilization of modern techniques such as artificial intelligence and modern techniques in concrete industry for the prediction of strength parameters by utilizing several wastes and additives 2 , 17 &#; 19 . A repair good improves the function and performance of structures, restores and increases their strength, provides water tightness, and prevents aggressive environment to steel surface durability 20 .

Structure stability and enhancement of strength properties are the main goals of engineers. However, researchers mostly considered green and sustainable construction while enhancing the strength properties; therefore, they try to limit the use of natural resources and widely used waste materials 1 . Recently, several innovations have been introduced in the construction industry globally in which concrete-related innovations took the lion&#;s share of the current period. However, with those innovations, still have several deficiencies need to be resolved. Concrete consumes a substantial amount of natural resources like cement, coarse and fine aggregate which is tread to the environment 2 , 3 . According to Alexander and Sakthivel 4 , 5 , to reduce the use of natural resource consumption and achieve sustainability in buildings, we should utilize abundantly available waste material as a natural resource replacement. It is vitally necessary to use creative, green, lightweight, and affordable materials, particularly those that can serve the intended purposes, of preserving the world's natural environment and guaranteeing the sustainability of natural resources 6 &#; 9 .

Materials and methods

The materials used in the research process were cement, fine aggregate and coarse aggregate, three types of gabions (welded wire mesh, hexagonal wire mesh and expanded metal wire mesh) reinforcement bar, super plasticizer admixture and potable water. The physical and chemical composition properties of these materials have been duly investigated.

The chemical reaction associated with the decarbonation of limestone at high temperature, which produces cement, releases a substantial amount of carbon dioxide38. Ordinary portland cement (OPC) used in this study which satisfies the standard of the building codes of Ethiopia. The specific gravity properties of OPC were 3.15, Standard consistency was 34% and initial setting time was 40 min. The consistency and setting time test was conducted based on the ASTM-C191-. The curing days greatly affect the concrete compressive strength. On 28 days of curing, the concrete gains the highest strength. The current study chose 14 curing days due to the superplasticizer admixture with 0.2% in concrete which enhances earlier concrete strength. An admixture known as superplasticizer with a proportion of 0.2% was used in order to facilitate the strength-gaining period of the concrete. Potable water readily available in the local area was used which satisfies the drinking standard of Ethiopia.

River sand readily available which satisfies the requirement to be used in concrete casting was used. The sieve analysis of fine aggregate is conducted in the laboratory to study the physical properties as depicted in Table . Lightweight sand provides the same tensile strength as natural sand but lowers the compressive strength of Ferro-cement specimens40.

Table 1

Sieve size in mmWeight of sieve (gm)Weight of sand&#;+&#;retained sand(gm)Mass retainedPercent retained (%)Cumulative percent retained (%)Percentage passing4..252..752..57..251...183.90....650..891.158.850..Pan.Open in a separate window

The sand used in the research was tested for its basic properties. The laboratory tests made fine aggregate are sieve analysis, specific gravity, and silt content tests. The majority of the sand used was passed through a 4.75 mm sieve. The sieve analysis test was performed based on ASTM -C136/C136M-. The gradation test result shows that the sand is well-graded sand with a fineness modulus of 2.25 as shown in Fig.  .

Since the presence of more silt or organic matter made concrete or mortar decrease the bond between the materials to be bound together and hence the strength of the mixture. The finer particles do not only decrease the strength but also the quality of mixture produced resulting in fast deterioration. Therefor it is necessary that one make a test on the silt content and checking against permissible limits. According to the Ethiopian Building Code Standard, if the silt content of the sand is more than 6% it shall not be used for construction. But the result (2.45%&#;<&#;6%) complies with the standard and we used the sand material as shown in Table .

Table 2

Sample numberAmount of silt deposit above the sand (A)Amount of clean sand (B)Silt content&#;=&#;(A/B) * 100%11 mm46.52.15%21..13%31.248.52.06%Average silt content2.45%Open in a separate window

The main objective of the laboratory test is to determine the specific gravity and the water absorption capacity of fine aggregate. The test has been made according to ASTM-C-128-97 manual. Though the aggregates and sand we used were from a construction site on the main campus it has been found that duly studying the behavior of the materials is an important stage since it affects the final output of the concrete cast by the materials. Table depicted the outcomes of specific gravity and water absorption of fine aggregate.

Table 3

NoTrial number123Average1Weight of oven dry specimen in air, in gm (A)Weight of pycnometer filled with water, gm (B)Weight of with specimen and water to the calibration mark, gm (C)Weight of saturated surface dry specimen, gm (S)Bulk specific gravity&#;=&#;A/(B&#;+&#;S&#;&#;&#;C)2.052..232.126Bulk specific gravity (SSD)&#;=&#;S/((B&#;+&#;S&#;&#;&#;C)2.242.302.402.317Apparent specific gravity&#;=&#;A/(B&#;+&#;A&#;&#;&#;C)2.532.672.702.638Absorption capacity&#;=&#;[(S&#;&#;&#;A)/A] * .110.627.769.1Open in a separate window

The aggregate that has used in the research had been examined for the fulfilment of ASTM-C-136-01 sieve analysis results and ASTM-C-127-88 standard test results for specific gravity determination42. Since the main intention of this research is to add aggregate for Ferro cement structures examining the gradation of the aggregate to be used is important. As a result, the sieve analysis results of the aggregate are depicted in Table . The aggregate has a maximum size of 14mm and most of the aggregate is retained in the 5mm sieve as shown in Fig.  . Since some codes recommend not using materials that are finer than 5 mm as aggregate a sieving process has been made before casting the concrete.

Table 4

Sieve size in mmWeight of sieve (gm)Weight of sand&#;+&#;retained sand(gm)Mass retained (gm)Percent retained (%)Cumulative percent retained (%)Percentage passing280.....222.....488..306.30........778..16Pan0...Open in a separate window

It is vital to determine the dry density in order to make the mix design calculations as well as to decide the compressive strength of the final cast concrete and as Ferro cement is a lightweight structure, we wanted to improve the material by lightweight aggregate in order to make it light as much as possible. The dry density of coarse aggregate is shown in Table . The specific gravity may be expressed as bulk specific gravity, bulk specific gravity [saturated surface dry (SSD)] or apparent specific gravity as shown in Table . Those parameters are used to determine the volume requirements and in determining the mix ratio calculations based on mass.

Table 5

Trial noWight of the mold in kg (A)Wight of the mold&#;+&#;filled aggregate
in kg (B)Wight of the retained aggregateVolume of the mold (m3)Density in (kg/m3)12....*.....*.....*.24Average density595.68Open in a separate window

Table 6

Trial noWt. of oven dry sample (gm)Wt. of SSD sample (B)Wt. of SSD in water (C)
(gm)Bulk specific gravity
A/(B&#;&#;&#;C)Bulk specific gravity
B/(B&#;&#;&#;C)Apparent specific gravity
A/(A&#;&#;&#;C)Water absorption capacity in %.32.192.212.241..12.222.242..52.222.252.281.1Average values2.212.232.261.07Open in a separate window

Gabion (steel wire) meshes are thin steel wires has served in many fields of real-life applications though in different orientations and different mechanisms of applications. Most of the applications of gabion include that uses as a fence, uses in soil and water conservation works to prevent excessive erosion, and in some developed societies as building decoration works as well. The materials have very flexible behavior to be used in making different forms of ornamental works like different shapes in places where people used to recreate.

Different types of meshes are available almost in every country in the world. Two important reinforcing parameters are commonly used in characterizing Ferro cement and are defined as the volume fraction of reinforcement; it is the total volume of reinforcement per unit volume of Ferro cement. The specific surface of the reinforcement is the total bonded area of reinforcement per unit volume of the composite. The principal types of wire mesh currently being used in this research are hexagonal (chicken) wire mesh welded square wire mesh and expanded metal mesh among the available steel wire meshes. The addition of wire mesh layers as reinforcement improves flexural strength, cracking behavior, and energy absorption capability greatly.

Hexagonal or chicken wire mesh is readily available in most countries, and it is known to be the cheapest and easiest to handle. The mesh is fabricated from cold drawn wire which is generally woven into hexagonal patterns. Special patterns may include hexagonal mesh with longitudinal wires. The chicken wire mesh used in this research has a thickness of 2.2mm and opening spacing of 35mm as shown in Fig.  a. The yield strength of the steel wire mesh is considered as 450Mpa as taken from the manufacturer&#;s specifications.

In welded square wire mesh, a grid pattern is formed by welding the perpendicular intersecting wires at their intersection. This mesh may have the advantage of easy molding into the required shape; it has the disadvantage of the possibility of weak spots at the intersection of wires resulting from inadequate welding during the manufacture of the mesh. Welded square wire mesh with a thickness of 0.7mm was used during the research as shown in Fig.  b.

Expanded metal mesh is formed by cutting a thin sheet of expanded metal to produce diamond shape openings. It is not as strong as woven mesh, but on cost to strength ratio, expanded metal has the advantage. This type of mesh reinforcement provides good impact resistance and crack control, but they are difficult to use in construction involving sharps curves as shown in Fig.  c.

As recommended by43 that the design strength for the mesh reinforcement shall be based on the yield strength fy of the reinforcement but shall not exceed 690 N/mm2. Design yield strengths of various mesh reinforcements are shown in the Table as per the data from the material manufacturers and recommendations of Sharma studies. These shall be used for design only when test data are not available. In the research, we used this data for qualitative comparisons of the results got from the laboratory tests.

Table 7

Welded square wire meshHexagonal meshExpanded metal meshLongitudinal barsYield strengthfy N/mmEffective modulus(Er) Long. (N/mm2)104,,,,000(Er) Trans. (N/mm2)69,,,000&#;Open in a separate window

Mix design

The chemical composition of the cement, the nature of the fine aggregate, coarse aggregate, and the water-cement ratio are the major parameters governing the properties of the concrete. The concrete matrix is designed for its appropriate strength and maximum denseness and impermeability, with sufficient workability to minimize voids and to avoid map cracking. Cement mortar used in ferro concrete acts as a good insulator and the reinforcing wire mesh can reduce surface upheaval better than plain concrete44. Precautions are necessary to maintain the small cover and in the selection of aggregates, mixing, placing, and curing. Mortar recommended for Ferro cement shall comprise particles or aggregates of limited size. The mortar matrix usually comprises more than 95 percent of the Ferro cement volume and has a great influence on the behavior of the final product. The cement mortar should be mixed with a proper sand-cement ratio (ranging from 1.5 to 2.5 by weight) and water-cement ratio (between 0.35&#;0.45 by weight) in order to achieve sufficient plasticity and facilitate easy casting. Many defects are possible due to a lack of complete infiltration and consolidation.

To avoid caking, the ingredients for mixing concrete, including the water, should be precisely batched by weight before poured into the mixer45. The sand-cement ratio should be calibrated to generate a fluid mix for the first infiltration of the armature, followed by a stiffer, more highly sanded mix at the finish, whereas the w/c should be as low as feasible46. As recommended that the CS should be at least 35 MPa for 28 days of curing with cube dimension of 150&#;×&#;150 mm47. According to the recommendations for ferroconcrete, we have used a water-cement ratio of 0.4 and a material proportion of 1:1.5:2 (cement, sand, and coarse aggregate respectively to cast a concrete of grade more than 35 Mpa. Since the concrete material is expected to possess good strength in a small thickness, the result is considered as ferro cement material improved by the addition of coarse aggregate of maximum size 14 mm taking in to account the opening of the gabion. Normally the slump of fresh concrete we cast was a true slump with 37mm as shown in Fig.  . Admixtures or additives have been added to improve the performance and workability of the concrete.

Open in a separate window

Due to the lack of readily available standard molds in the laboratory temporary molds were prepared for the flexural specimens and for the energy absorption test specimens. The molds were prepared in such a way that the dimension of the inner mold satisfies the requirement of the standard molds. Two types of molds were prepared with inner dimensions of L:W:D (500:100:100) in mm for flexural mold and the second type slabs for energy absorption test with inner dimensions L:W:D is 400mm:300mm:75mm, by considering the two-way aspect ratio and the deep beam effect which shall be greater than 4 to avoid deep beam effect.

Contact us to discuss your requirements of concrete slab mesh. Our experienced sales team can help you identify the options that best suit your needs.