Professional Documents
Culture Documents
Faculty
Prof. Anil Pawade
Year 2020-2021
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ABSTRACT
The paper aims to bring out the benefits of using ferro-cement over other materials. The
properties of this material like the thickness which less than any other material with such
good tensile strength can be a option for various needs. Since in India many architects and
engineers though having known about this material use this material very less this paper
brings into notice like easy self-handy properties, strength related properties, environment
related properties that will encourage this use of material in construction field. As this
material is also resistant to many disasters up to a certain level this can be used to fight
back various problems of property loss, time for rebuilding it, cost required for rebuilding
homes, etc this material can be a quick solution to such natural problems.
1. INTRODUCTION
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2. HISTORICAL BACKGROUND
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(Source: http://www.engineersbay.com/ferrocement-history-and-development/)
3. COMPONENTS OF FERROCEMENT
Ferrocement consists of cement, sand, wire mesh and various admixtures. The main
difference between RCC and ferrocement is the scale. RCC uses large size reinforcing bar
as compared to wire/mesh in Ferrocement. Reinforced concrete consists less volume of
the metallic part as compared to that of ferrocement. It does not contain large size
aggregate as used in RCC only cement mortar is used. At times, depending upon the
structural requirement Ferro-cement may consists of large size bars along with wire mesh.
The number of layers of wire mesh to be provided depends upon the applications for
which it is going to be used. Typical cross section of ferrocement are shown in image 1.
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Sand particle should be one third of the opening of the mesh so that it penetrate in the
reinforcement mesh.
3.2 MESH REINFORCEMENT
4 .CONSTITUENTS OF FERROCEMENT
4.1 CEMENT
The cement is fresh, uniform consistency and free from lumps and foreign matter.
Generally Portland cement of 43 or 53 grade is used.
4.2 AGGREGATE
Well graded and washed river sand passing 2.36mm IS sieve. Size of aggregate depends
on size of mesh and spacing between mesh. For 13 mm mesh opening max size of
aggregate 3.25mm, 1/4th its opening size. The fine aggregate should be clean, free from
organic matter.
4.3 CLEAN WATER
In Ferro cement, the water used should be fresh, clean and fit for construction purposes;
pH equal or greater than 7 and free from organic matter.
4.4 STEEL
Three basic types of meshes are Weld mesh, Fine wire mesh in form of woven square
mesh and interlocked hexagonal wire mesh, expanded metal and Crimped wire mesh.
5. STEPS
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Image source: http://oer.nios.ac.in/wiki/index.php/File:Ferrocement_image-2.png
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Image source: http://oer.nios.ac.in/wiki/index.php/File:Ferrocement_image-2.png
5.6 TESTING
The wall panels constructed in Ferro cement are removed from tank after curing of 28
days. Testing was carried under UTM machine for flexure test.
Two Point Loading System
Next the panels were loaded UTM Machine for under two point loading and load and
deflections
5.7 PRECAUTIONS ABOUT CURING
Though Ferro cement structures gain sufficient strength in one weeks’ time, curing should
be done for about 26 days.
1. Ferro cement technology can be used in all fields of construction including buildings,
industrial structures, water retaining structures, earth retaining structures, space structures
and precast concrete products
2. It is cost effective to use Ferro cement in low rise mass housing than RCC
3. Proposed where shapes are complicated and shuttering is not possible
4. Ideal for housing in earthquake zones.
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5. Ideal for use in remote locations which has shortage of material and skilled labour.
6. Ideal for structures which require reduced load on foundation
7. Ideally used in areas which has shortage of material like brick, wood and stone
aggregate.
8. Soundproof, heat proof and waterproof structure
9. Fabricate factory made modular panels.
As thin structural elements, ferrocement has been used in numerous applications ranging
from engineered structures to architectural applications (Paramasivam, 2011) such as
sheets, boards, shells, hulls, and also sandwich type construction using thin skins, and
constructions where the reduction of self-weight, improved water permeability and
development of very fine crack widths are essential (Sakthivel & Jagannathan, 2011).
7.1 STRUCTURAL APPLICATIONS
Ferrocement can be used in various structural members subjected to different type of
stresses. As a compression member, hollow columns with horizontal stiffners can be cast
in ferrocement. Columns or walls in concrete, RCC, stone or brickwork can be encased in
ferrocement to increase their strength due to confinement. Members subjected to
membrane stresses like shells, domes, pyramids can be cast in ferrocement very easily;
and being a homogenous material, full section of member is utilized in resisting the
membrane stresses. A ferrocement hyperbolic paraboloid shell structure was constructed
by the student chapter of the American Society of Civil Engineers at the University of
Illinois in Chicago, U.S.A. in 1977 (Naaman, 2000). Funded by the International
Development Research Centre of Canada, two proptotype cylindrical water tanks for the
collection of rainwater were designed, constructed, and tested for use in the rural areas of
the Phillipines (Paramasivam et al. 1990). A greater use could be made of ferrocement in
water-retaining constructions and other similar constructions where crack width is a
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design criterion (Al-Kubaisy and Jumaat, 2000). Because of its very small crack widths
under service load and it superior extensibility, ferrocement provides excellent leakage
characteristics for applications in water tanks; moreover, should pressure increase,
ferrocement stretches to allow higher leakage and acts as a safety valve, thus, it does not
fail (Naaman, 2000).
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deepens up due to increase in corrosion and subsequently, peeling of concrete cover or
spalling of concrete takes place. Use of proper repairing materials and methods of
damaged or deteriorated RCC structures is a necessity not only to serve the intended
service life but also assure the safety of buildings (Masood et al. 2003).
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Step 2: Exposing the original reinforcing bars and scraping of corrosive layers of reinforcement
and applying anti-corrosive paints (if any) or cutting and replacing the corroded reinforcement
Step 3: Roughening the concrete surface, and placing chicken and/or galvanised wire/ weld
mesh in position and the mesh should get fixed/ embedded to original slab/beam/column
reinforcement. Use skeletal reinforcement, if required.
Step 4: Applying cement mortar on the reinforcing wire-mesh by hand or through spraying
(similar to guniting/ shotcreting methods)
Step 5: Provide necessary curing for 28 days.
Alternatively, ferrocement membrane protective layer can be carried out. In this, layers of
closely spaced wires can be used on to the RCC surfaces to prevent crack widening. The
cement matrix is in proportion of about 1:2 and has admixtures which reduce shrinkage
and develop early high strength. The matrix is vibrated locally using light vibrating tools.
Finish of the membrance is just like plaster.
The advantage of this technology is that it is very flexible, and can be used to create any
shape and form of structure.
1. Ferro cement planks & panels can be used for construction of beams, columns,
floor, roofs, walls, chajjas and lintels.
2. It can be used in combination with plain cement concrete or reinforced cement
concrete.
3. Ferro cement being a thin material single piece panel of size up to 4.5m x 4.5m or
more can be manufactures as floors and walls. Large span beams, roofs can also be
constructed.
4. Ferro cement membrane lining is used for water proofing of terraces, basements,
tanks.
5. Ferro cement water proofing is the only treatment where reinforcement is used in
the form of wire mesh layers and vibrations are provided in the matrix layers.
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Therefore, ferrocement water proofing treatment should generally last longer than
conventional.
6. Ferro cement is a good material for elevation treatment. Since it is constructed in
these sections, it contributes negligible dead weight, and at the same time it is
crack resistant, water proof and strong.
7. Ferro cement is a very good fire resistant material having capacity to resist fire up
to 750°C for long period of 48 hours and even more.
8. Ferro cement can be modified to resist even high temperatures, say 1200°C to
1500°C.
9. Ferro cement buildings are better pollution and fire resistant as compared to RCC.
Therefore, ferrocement buildings are preferable to RCC for functional VIP and
strategic buildings.
9. APPLICATIONS OF FERROCEMENT
Used as planks for shelves in housing projects replacing costly wooden planks
Ferro-cement components are Used in Rural areas for low cost housing
Recently Ferro-cements are used in some residential and industrial buildings also
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Image source: - https://happho.com/ferro-cement
With the help of Ferrocement material, many Precast Ferro cement products are
made like Septic Tanks, Water Tanks and Designer Roofs.
Designer Roof is a new concept in the building industry. All products are eco-
friendly and its designs naturally blend with the environment.
Famous FC Products are: Designer Roofs, Dome, Septic Tanks, Roofing slabs, Water
Tanks, Drainage channels, Iron Removal Plant, Long bench, Boats and Vessels.
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Tensile strength of Ferro-cement is depended on write mesh system which it has. Tensile
strength of Ferro-cement varies depending upon number of layers of wire mesh, spacing
between the mesh, shape of the wire mesh orientation of wire mesh in it.Tensile behavior
of Ferro cement is entirely different as compared to that normal reinforced concrete;
specific surface area of reinforcement is larger diameter bars which are distributed
uniformly. Tensile strength of Ferro-cement is limited to the tensile strength of
reinforcement taken alone the direction of loading as mortar layer above itself has very
less tensile strength. Tensile strength in Ferro-cement is of same order as that of
compressive strength in it
First cracking is one of the important parameters on which the cracking pattern of ferro-
cement depends on. First cracking can be subjective and it depends upon how the cracks
are viewed through microscope or through naked eyes. The first crack width may range
anything between 0.005 mm to 0.1 mm depending upon how they are noticed. First
cracking basically means the first deviation which occurs in the load deflection curve of
the Ferro-cement material. The first cracking strength required to develop crack depends
upon the specific surface of reinforcement. It increases with increase in specific surface
area of reinforcement
The Ferro-cement composites first behave as linear elastic
until the first crack is appeared. After the first crack appears the multiple cracking stage
starts, number of cracks starts to form but the crack width remains constant and
propagates in the direction where the matrix starts to fail. Now the reinforcement starts to
yield and will continue till fatigue failure occurs, during this number of cracks formed are
few but the width of cracks already formed starts increasing
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(Image source: https://issuu.com/irjet/docs/irjet-v4i6536)
10.3 COMPRESSION
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10.4 LIQUID RETAINING CAPACITY
Ferro-cement has got wide application in retaining water like in liquid storage tanks.
Leakage starts in the tank made up of Ferro-cement after the first cracking has occurred.
The leakage increases in the cracked reinforcement as average crack width increases and
with decrease in the wall thickness. With increase in the volume or specific surface area of
the wire mesh the leakage decreases as the crack width and number of cracks formed
decreases. The crack widths formed in Ferro-cement are much smaller in size as compared
to those formed in normal reinforced concrete as a result of it the leakage occurring in
Ferro-cement is comparatively less
Fire resistance can be defined as the ability of structural elements to resist fire severity,
materials of the element geometry etc are the factors on which resistance of concrete
elements depend on. Based on various studies carried on Ferro-cement by different
researchers on its fire resistance capability different results were obtained. Most of the
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scholars agreed on that by providing a Ferro-cement jacket on reinforced structures their
resistance to fire increased. This property of Ferro-cement was due to its specific heat
capacity which was slightly higher than those of concrete cover and thus it can absorb
more heat as compared to that of concrete cover. Structure members are weakened when
exposed to high temperatures causing the structures to collapse. it was found from the
studies that by using thin layer of Ferro-cement as jacketing to the reinforced members the
surface spalling reduced due to reinforcing wire mesh. Increase in wire mesh content in
Ferro-cement significantly improved flexural and toughness under normal conditions,
after fire exposure the wire mesh content had no longer significance on the two
mechanical properties. Moreover, by increasing the wire mesh content the insulation
property becomes poorer which is basically due to decrease in specific heat capacity of
Ferro-cement. On the other hand, increasing the mortar covering resulted in improved
insulation performance. Ferro-cement behaviour under fire is still in its formative years a
greater number of experiments is needed to be carried out before concluding properties of
Ferro-cement relating resistance to fire.
11.1 ADVANTAGES
• Given a large impact or point load, shell will deform and resulting in cracks, however
structure will remain intact.
• Less use of cement and steel for any given section compared with RCC
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• Reduction in self weight.
• Reduction in cost compared to RCC
• Requires only semi-skilled labour
• Requires neither scaffolding, shuttering, concrete mixer or vibrator
• High degree of permeability and resistance to Cracking
• Economical compared to components built with steel, concrete.
11.2 LIMITATIONS
• The common causes of failure of ferrocement are steel corrosion and incomplete mortar
penetration.
• The need of a casting space and working area to prefabricate the elements.
• The need for a properly applied curing method
• If the elements are not manufactured on the site transportation may add to the cost.
The temple has been conceived with a series of 24 domes of varying sizes and shapes
with largest being about 8 m dia and 18 m high and smallest one of 2.2 m dia and 1.8 m
high. The bigger dome is made up of about 128 individual petals of different shapes and
sizes of about 4 m2 area each. These are precast and then erected & assembled (8 petals
at each level) into in-situ ferrocement ribs.
Other domes are made up of pieces varying from 4 pieces per dome to 50 pieces per
dome.
The mortar for this high performance ferrocement has been designed after a series of tests
using different cements, fly ash, micro-silica, fibres and superplasticizers. The mortar is
virtually impermeable and develops compressive strengths of the order of 60 N/mm2.
The advantages of precast ferrocement have been mainly the excellent compaction,
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durability, very good curing and substantial saving in time. All the pre-casting was
completed well before the slabs on which the domes were to be erected. Thus as soon as
slab was cast and curing of slab was completed the erection of Shikhara was taken up.
Overall saving in time was about 8 months compared to in-situ RCC Domes. There was
also substantial saving in cost due to saving of material, formwork and reduced dead load
on substructure.
ure
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12.2 CONSTRUCTION OF FOLDED PLATE ROOF IN
FERROCEMENT, FOR SWAMI SAMARTH MANDIR AT HEDVI,
MAHARASHTRA
12.2.3 Reason for precautions: Heavy Rainfall and Expected long life of
Monumental structure.
12.2.4 Other to specify: The lower structure is done in RCC beams construction.
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13. CONCLUSION
This study has brought out that ferrocement is an innovative material and the ready
availability of materials and ease of construction make it suitable in developing countries
for housing, and water and food storage structures. Ferrocement is found to be a suitable
material for repairing or reshaping the defective RCC structural elements and enhancing
its performance. The applications of ferrocement are capturing almost all the fields of
civil engineering but there is a dearth of research backing and a rationale design base to
construction of ferrocement structures. As the performance of ferrocement is greatly
dependent on the characteristics of the reinforcing mesh, there is a need to determine and
specify an optimum range of properties for the mesh, such as wire spacing, wire diameter,
and the characteristics of the mesh system. This is only a review study and experimental
research on new building materials for use in ferrocement construction or combinations of
meshes and fibers are needed. The standard methods of ferrocement construction and
effect of shape due to which novel forms are generated have to be researched upon and
benefits brought out. Considering the unique features, ferrocement will no doubt be one of
the most important structural alternatives for RCC and a repair material in the future and
thus has a great potential for developing and developed countries alike.
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14. REFRENCES
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