ferro-cement

FERROCEMENT

WHAT IS FERROCEMENT?• Definition of ferrocement reported

by ACI Committee 549, 1988Ferrocement is a form of reinforced concrete using closely spaced multiple layers of mesh and/or small diameter rods completely infiltrated with, or encapsulated in, mortar.

• In 1940 Pier Luigi Nervy, an Italian engineer, architect and contractor, used ferrocement first for the construction of aircraft hangars, boats and buildings and a variety of other structures.

• It is a very durable, cheap and versatile material.

Section of ferrocement

COSTITUENTS OF FERROCEMENT

• Cement: The cement should be fresh, of uniform consistency and free of lumps and foreign matter.

• Fine Aggregates :Normal weight fine aggregate clean, hard, strong, free of organic impurities and deleterious substances and relatively free of silt and clay.

• Water :Potable water is fit for use as mixing water as well as for curing ferrocement structures.

• Admixture : Chemical admixtures used in ferrocement serve purposes OF water reduction, with strength and reduces permeability; air entrainment, which increases resistance to freezing and thawing; and suppression of reaction between galvanized reinforcement and cement

•Reinforcing mesh :The function of the reinforcing wire mesh in the first instance is to act as a lath providing the form and to support the mortar in its green state.• Skeletal Steel :Skeletal steel is generally used for making the framework of the structure upon which layers of mesh are laid

• Coating :vinyl and epoxy coatings were found to be the most successful organic coatings.

Types of wire mesh reinforcement used

Three-dimensional mesh

CONSTRUCTION

• The desired shape using ferrocement may be built from a multi-layered construction of chicken wire or other steel mesh.

• Over this finished framework, an appropriate mixture of cement, sand and water is spread out

• A considerable amount of time may be necessary for the material to fully cure and reach its final strength

•MORTAR MIXING:MORTAR MIXING:The mortar The mortar must be dense and compact. A must be dense and compact. A general mix is 1 part cement, 2 general mix is 1 part cement, 2 parts sand. Water is added parts sand. Water is added roughly 0.4 parts water by weightroughly 0.4 parts water by weight•MORTAR APPLICATION: MORTAR APPLICATION: Fingers and trowels are used for Fingers and trowels are used for mortar placement in the mesh mortar placement in the mesh structure. Mortar guns are not structure. Mortar guns are not recommended recommended •CURING.CURING. It should be kept moist It should be kept moist at least 7 days and protected from at least 7 days and protected from the sun and wind.the sun and wind.

CHALLENGES

COMPOSITE PROPERTIES• Ferro cement has very high tensile strength- to weight

ratio and a superior cracking behavior• Low w/c ratio produces an impermeable structures• Ferro cement structures have high durability ,less

shrinkage, and low weight.FERROCEMENT COMPOSITES HAVE:• Thickness 6 to 50 millimeters• Steel cover 1.5 to 5 millimeters• Ultimate tensile strength up to 34 MPa• Allowable tensile stress up to 10 MPa• Modulus of rupture up to 55MPa• Compressive strength up to 28 to 69MPa

ADVANTAGES• Its basic raw materials are readily

available in most countries.• It can be fabricated into any desired

shape.• The skills for ferrocement

construction can be acquired easily.• Heavy plants and machinery are

not involved in ferrocement construction.

• Being labor intensive, it is relatively inexpensive in developing countries.

• It is widely used due to the low self weight, durability & versatility.

DISADVANTAGES

• Structures made of it can be punctured by collision with pointed objects.

• Corrosion of the reinforcing materials due to the incomplete coverage of metal by mortar.

• Large no of labors required• It is difficult to fasten to

ferrocement with bolts,screws,welding and nail etc..

• Tying rods and mesh together is especially tedious and time consuming.

APPLICATIONS• HOUSING:Ferrocement houses

utilizing local materials such as wood, bamboo or bush sticks as equivalent steel replacement have been constructed in Bangladesh & Indonesia

• MARINE :Ferro cement can be effectively used for various water supply structures like well casings for shallow wells, water tanks, sedimentation tanks, slow sand filters and for sanitation facilities like septic tanks, service modules and sanitary bowls

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•RURAL ENERGY :In Thailand and India, biogas digesters and biogas holders have been constructed with ferrocement which lead to a considerable cost reduction. •Miscellaneous Applications :Ferro cement is proving to be a technology that can respond to the diverse economic, social and cultural needs of man.

FERRO CEMENT ROOFING TECHNOLOGY

WORKS CARRIED OUT

• Al-Ameen College, Bangalore• Leela Palace Bangalore• Sai Super Specialty Hospital,

Whitefield, Bangalore• Kolkata Commercial Plaza,

Kamaraj Road, Bangalore• Dome Residence for I. K Hospital,• Alipur Sai temple, Kanakapura

Road.

AL AMEEN COLLEGE

LEELA PALACE

ON GOING PROJECTS• AP gem and Jewelry Park, Hyderabad

• .Phonix uppel, Hyderabad.

•  Vydehi. White field. Bangalore. 

• Don Basco college, Mysore Road, Bangalore.

•  Pre-Cast housing, Alipur.

•  

CONCLUSION•Ferro-cement come into wide spread use only in the last two decades and still in its infancy.•Sufficient design information is available and adequate field experience has been acquired to enable safe design and construction of Ferro-cement structures.•Whether it can economically compete with alternate materials depends on the type and location of application.•However, innovative structures in different parts of the world have clearly indicated the unique, unmatched properties of this material and therefore the vast potential waiting to be explored

REFERENCES

• www.appropedia.org/Original:Ferrocement_Applications_in_Developing_Countries_9"

• Ferrocement and Laminated Cementitious Composites by Antoine E. Naaman

• www.concure.com• www.fasiformsystem.com• www.smithconcretenc.com• www.wikipedia.com