A

SEMINAR REPORT
ON
“COST EFFECTIVE FERROCEMENT SMALL HOUSE”

By

Vijendra Kumar
ROLL NO.1005200021

Under the Guidance of

Prof. S.P. Shukla

DEPARTMENT OF CIVIL ENGG.

INSTITUTE OF ENGINEERING & TECHNOLOGY
SITAPUR ROAD, LUCKNOW-226021
[2013-14]

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 ACKNOWLEDGEMENT
Keeping me with the tradition of torch bearer of the nation, I would like
to highly acknowledge and pay respect to one and all associates with seminar
report at different stages.
I owe my sincere gratitude and humbleness to our respected Head of the
Department, Dr. J.B. Srivastava,Dr.S.P.Shukla, Er.V.K.Singh (Seminar
Incharge) & all my teachers for being a guiding light, and whose pursuits and
confidence in me as an instant booster during this endeavor. They also helped
me in understanding basic aspects of the seminar.
My parents and friends also hold a special mention here for believing in
me and supporting me.

Vijendrakumar
Roll no. 1005200021
Civil Engg.
I .E.T. Lucknow

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 Contents
TOPIC page no.

1.0 INTRODUCTION...................................................................................................1
2.0 NEED FOR COST EFFECTIVE HOUSES BUILDING TECHNIQUES............. 1
3.0 HISTORY OF FERROCEMENT............................................................................2
4.0 MATERIAL USED................................................................................................ .3
4.1.0 Cement...................................................................................................... 3
4.2.0 Fine Aggregates.........................................................................................3
4.3.0 Water........................................................................................................ .3
4.4.0 Admixture................................................................................................ .4
4.5.0 Mortar Mix................................................................................................4
4.6.0 Reinforcing Mesh......................................................................................4
4.7.0 Skeletal Steel.............................................................................................5
5.0 METHODS OF FERROCEMENT..........................................................................6
5.1.0 Armature method.......................................................................................6
5.2.0 Closed mould systems...............................................................................6
5.3.0 Integrated mould system........................................................................... 6
6.0 CONSTRUCTION METHODS...............................................................................6
7.0 TEST ON FERROCEMENT SPECIMEN...............................................................8
7.1.0 Flexure.......................................................................................................8
7.2.0 Tension...................................................................................................... 8
7.3.0 Compression.............................................................................................. 8
7.4.0 Design of Specimens....................................... ..........................................8
7.5.0 Test Setup...................................................................................................9
8.0 PROPOSED SMALL HOUSE.................................................................................10
8.1.0 Features of Proposed House.......................................................................10
8.1.1 Light Roofing System............................................................................... 11
8.1.2 Joint Details................................................................................................12
8.1.3 Foundations................................................................................................ 13
8.1.4 Openings.....................................................................................................13
8.2.0 Tentative Cost................................................................................................ 13
8.3.0 Flexibility of Extension................................................................................. 14
9.0 ADVANTAGES & DISADVANTAGES OF FERROCEMENT ............................16
10.0 OTHER USES OF FERROCEMENT COMPONENT..........................................17
11.0 CONCLUSION........................................................................................................17
References

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1.0 INTRODUCTION
Ferrocement is a highly versatile form of reinforced concrete made of wire mesh, sand, water,
and cement, which possesses unique qualities of strength and serviceability. It can be
constructed with a minimum of skilled labour and utilizes readily available materials.

Ferrocement has a very high tensile strength-toweight ratio and superior cracking behavior in
comparison to conventional reinforced concrete. This means that thin ferrocement structures
can be made relatively light and watertight. Hence, ferrocement is an attractive material for
the construction of prefabricated housing units, boats, barges, and other portable
structures.Figure 1. show all the component of ferrocement wall.

Figure 1. Piece of ferrocement wall

2.0 NEED FOR COST EFFECTIVE HOUSES BUILDING TECHNIQUES

Today we are living in the world of raising prices. Considering the cost of cement, sand,
aggregates and steel ,the need to adopt Cost effective technology in Construction has become
imperative, so that the constructing a house is within the reach of a common man.

But nowadays we are constructing most our houses by framed structure concept made of
columns and beams. This need lot of Cement and steel .For a simple structure like house we
can adopt cost effective time technology to save cost

The ferrocement has been used like an effective alternative that, on the one hand, offers
durable houses and of good quality, and , on the other hand, it offers a constructive system
with base in not described intensive manpower.

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3.0 HISTORY OF FERROCEMENT

Joseph-Louis Lambot’s original French patents on wire-reinforced boats were issued in 1847
not long after the development of portland cement. This was the birth of reinforced concrete,
but subsequent development differed from Lambot's concept. The technology of the period
could not accommodate the time and effort needed to make mesh of thousands of wires.
Instead, large rods were used to make what is now called standard reinforced concrete, and
the concept of ferrocement was almost forgotten for a hundred years.

In the early 1940's, Pier Luigi Nervi resurrected the original ferrocement concept when he
observed that reinforcing concrete with layers of wire mesh produced a material possessing
the mechanical characteristics of an approximately homogenous material and capable of
resisting high impact.

Figure 2. Model of ferrocement boat made by Joseph-Louis Lambot’s(1847)

Thin slabs of concrete reinforced in this manner proved to be flexible, elastic, and
exceptionally strong. After the Second World War, Nervi demonstrated the utility of
ferrocement as a boatbuilding material. His firm built the 165-ton motor sailer Irene with a
ferrocement hull 1.4 inches (3.6 cms) thick, weighing 5 percent less than a comparable wood
hull, and costing 40 percent less. Other ferrocement boats have shown similar practicality,
and their number is steadily increasing. The recent emphasis on the use of ferrocement for
boatbuilding has obscured Nervi's noteworthy applications to buildings, begun in 1947. After
building a small storage building in his own construction yard to demonstrate its versatility
and strength, he covered the swimming pool at the Italian Naval Academy with a SO-foot
vault and followed this with the famous Turin Exhibition Hall-a structure spanning 300 feet.
He subsequently built several other long-span structures of ferrocement. Nervi's work and
subsequent applications presage an application of ferrocement on land that may overshadow
the fresh-water applications.

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 Figure 3. Ferrocement-roofed warehouse in Tortona, Italy, for storing salt, designed
and built by Nervi, 1950-51.

4.0 MATERIAL USED

4.1.0 Cement:The cement should comply with ASTM C 150-85a, ASTM C 595-85,
or an equivalent standard. The cement should be fresh, of uniform consistency and free of
lumps and foreign matter. It should be stored under dry conditions and for as short
duration as possible. Cement factors are normally higher in ferrocement than in
reinforced concrete. Mineral admixtures, such as fly ash, silica fumes or blast furnace
slag, may be used to maintain a high volume fraction of fine filler material. Rice Husk
Ash (RHA) cement can be economically used as partial replacement of cement in mortar
mixes. When RHA does not exceed 35% by weight of the blended cement, the compressive
strength at 28 days is similar to that of Type I Portland Cement Mortar.

4.2.0 Fine Aggregates:Normal weight fine aggregate (sand) is the most common
aggregate used in ferrocement. It should be clean, hard, strong, free of organic impurities
and deleterious substances and relatively free of silt and clay. It should be inert with respect
to other materials used and of suitable type with respect to strength, density, shrinkage
and durability of the mortar made with it. Grading of the sand is to be such that a
mortar of specified proportions is produced with a uniform distribution of the
aggregate,which will have a high density and good workability and which will work
into position without segregation and without use of high water content. The fineness of
the sand should be such that 100% of it passes standard sieve.

4.3.0 Water:Water used in the mixing is to be fresh and free from any organic and
harmful solution which will lead to deterioration in the properties of the mortar. Salt

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water is not acceptable but chlorinated drinking water can be used. Potable water is fit for
use as mixing water as well as for curing ferrocement structures.

Figure 3. Material used in ferrocement

4.4.0 Admixture: Chemical admixtures used in ferrocement serve one of the following
four purposes: water reduction, which increases strength and reduces permeability; air
entrainment, which increases resistance to freezing and thawing; and suppression of
reaction between galvanized reinforcement and cement.

4.5.0 Mortar Mix:The reaction of port land cement and water results in formation of
hardened cement paste. The ranges of mix proportions recommended for common
ferrocement applications are sand-cement ratio by weight, 1.5 to 2.5, and water-cement
ratio by weight, 0.35 to 0.5. Fineness modulus of sand, water-cement ratio and sand-
cement ratio should be determined from trial batches to insure amix that can infiltrate
(encapsulate) the mesh and develop a strong and dense matrix. Water reducing admixtures
may be used to enhance mix plasticity and retard initial set, as with conventional
concretes. The behaviour of mortar is similar to that of plain concrete. The major distinction
is the size of the aggregate used. In general a good quality mortar is stronger and more
durable than good quality concrete; however, their basic response to the environment
is essentially the same.

4.6.0 Reinforcing Mesh:One of the essential components of ferrocement is wire mesh.

Different types of wire meshes are available almost everywhere. These generally consist of
thin wires, either woven or welded into a mesh, but the main requirement is that it
must be easily handled and, if necessary, flexible enough to be bent around sharp corners.
The function of the wire mesh and reinforcing rod in the first instance is to act as a
lath providing the form and to support the mortar in its green state. In the hardened state its
function is to absorb the tensile stresses on the structure which the mortar, on its own,would
not able to withstand. A structure is subjected to great deal of pounding,twisting and bending
during its life time resulting in cracks and fractures unless sufficient steel reinforcement
is introduced to absorb these stresses. The degree to which this fracturing of the structure is

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reduced depends on the concentration and dimensions of the embedded reinforcement.
The mechanical behavior of ferrocement is highly dependent upon the type, quantity,
orientation and strength properties of the mesh and reinforcing rod.

Figure 4. stress-strain relationship in wire mesh Figure 5. Different types of wire mesh

4.7.0 Skeletal Steel:Skeletal steel as the name implied is generally used for making
the framework of the structure upon which layers of mesh are laid. Both the longitudinal
and transverse rods are evenly distributed and shaped to form.

CURRENT RANGES OF FERROCEMENT COMPOSITION AND PROPERTIES

Table 1. Typical mortar composition

Portland cement Any type depending on application

Sand-to-cement ratio 1.0 to 2.5 by weight
Water-cement ratio 0.4 to 0.6 by weight
Recommendations Fine sand all passing U.S. sieve Number 8
and having 5 percent by weight passing
Number 100, with a continuous grading
curve in between

Table 2. Wire-mesh reinforcement

Wire diameter 0.5 to 1.5 millimeters
Type of mesh Chicken wire or square woven or welded
wire galvanized mesh; expanded metal wire
galvanized mesh; expanded metal
Size of mesh openings 6 to 25 millimeters
Number of mesh layers Up to 5 layers per 10 millimeters of thickness
Fraction volume of reinforcement Up to 8 percent in both directions
corresponding to up to 630 kilograms per
cubic meter
Specific surface of reinforcement 400 square millimeters per 100 cubic
millimeters in both directions

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 Table 3. Intermediate skeletal reinforcement, if used
Type Wires; wire fabric, rods; strands
Diameter 3 to 10 millimeters
Grid size 50 to 100 millimeters

Table 4. Composite properties

Thickness 6 to 50 millimeters
Steel cover 1.5 to 5 millimeters
Ultimate tensile strength 34 megapascals
Allowable tensile stress 10 megapascals
Modulus of rupture 55 megapascals
Compressive strength 28 to 69 megapascals

5.0 METHODS OF FERROCEMENT

There are basically three types of ferrocement. They are following:-

1. Armature system
2. Closed mould system
3. Integrated mould system

5.1.0 Armature menthod: In this method the skeletal steel is welded to the desired shape on
either side of which are tied several layers of stretched meshes. This is strong enough, so that
mortar can filled in by pressing one side and temporaly supporting other side.

5.2.0 Closed mould systems: Several layers of meshes are tied together against the surface
of the mould which holds them in position while mortar is being filled in. The mould may be
removed after curing or may remain in position as a permanent part of a finished structure. If
the mould is to be removed for reuse, releasing agent must be used.

5.3.0 Integrated mould system: Using minimum reinforcement any integral mould is first to
be considered to act as a framework. On this mould layers of meshes are fixed on either side
and plastering is done onto them from both sides. As the name suggests, the mould remains
permanently as an integral part of the finished structure. (e.g.double T-sections for flooring,
roofing etc.) Precaution should be taken to have firm connection between the mould and the
layers filled in later, so that finished product as a whole integral structural unit.

6.0 Construction Methods

 The desired shape may be built from a multi-layered construction of mesh, supported
by an armature, or grid, built with rebar and tied with wire.  For optimum
performance, steel should be rust-treated, (galvanized) or stainless steel.
  Over this finished framework, an appropriate mixture (grout or mortar) of Portland
cement, sand and water and/or admixtures is applied to penetrate the mesh. During
hardening, the assembly may be kept moist, to ensure that the concrete is able to set
and harden slowly and to avoid developing cracks that can weaken the system.

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   Steps should be taken to avoid trapped air in the internal structure during the wet
stage of construction as this can also create cracks that will form as it dries.
 Trapped air will leave voids that allow water to collect and degrade (rust) the steel.
Modern practice often includes spraying the mixture at pressure (a technique
called shotcrete) or some other method of driving out trapped air.
  To eliminating air where it contacts steel, modern concrete additives may include a
crylic liquid "admixtures" to slow moisture absortion and increase shock resistance to
the hardened product or to alter curing rates.
 Plastering to be done using simple equipment.
 One worker to impregnate mortar from one side while another worker holds a back-up
sheet on the other side.
 Excessive mortar build-up to be scraped off.
 Curing to be carried out for 28 days preferably in shade to avoid cracking by keeping
moist by frequent wetting, covering with jute sacks that retain water.

Figure 6. Placement methods: manual and shotcrete

Figure 7. Plastering of mortar

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7.0 TEST ON FERROCEMENT SPECIMEN

 Flexure
 Tension
 Compression
 Shear
7.1.0 Flexure–The load-carrying capacity of a ferrocement unit under flexural loading was
not dependent on only one variable. Some factors affecting its resistance were: the number of
layers of wire mesh, the volumetric fraction, the compressive strength of concrete, the
yield strength of wire mesh, the orientation of mesh and the dimensions of the section.

7.2.0 Tension–The nominal resistance of cracked ferrocement elements subject to pure

tensile loading was approximately equal to the load-carrying capacity of the mesh
reinforcement alone in the direction of loading. The nominal tensile capacity was directly
proportional to the effective cross-sectional area of the mesh reinforcement.

7.3.0 Compression - The assumption was that the nominal resistance of ferrocement
sections subjected to uniaxial compression was approximately equal to the load-carrying
capacity of the unreinforced mortar mortar (concrete) matrix. If the cracked mortar, after
subjecting the element to its ultimate load, was chipped off and was replaced with the
same mortar mixture, its compressive strength could be theoretically equal to the original
load-carrying capacity.

7.4.0 Design of Specimens

 Figure 8 shows the dimensions of the specimens. Hollow cylindrical specimens with
an outer diameter of 150 mm, a thickness of 32 mm, and a height of 200 mm were
subjected to axial compression. The shape of compression specimen was patterned
after the specimens used to study the stress-strain curve and the Poisson’s ratio of
ferrocement under axial compression (Rao et al., 1986). The mesh was rolled to
obtain the required number of layers. Plastic moulds for 150 mm x 300 mm (6” x
12”) concrete test cylinders were modified to create hollow cylindrical
compression specimens. As shown in Figure 5, filler made of a round wooden
platform with a cylindrical pole at the middle was used to attain the required
dimensions of a compression specimen.
 In casting the tension, flexure, and shear specimens, layers of plywood were cut
to form the shapes of the specimens as shown in Figure 9. The plywood pieces
were secured to the platform using 5-mm diameter steel bolts spaced at 100 mm
on center. Layers of wire mesh were placed in between the plywood pieces. Wire
mesh strands were pulled outward slightly to minimize sagging of the mesh and
to maintain the spacing between layers of mesh

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 Figure 8. Dimensioning of ferrocement specimen

Figure 9. mould for making ferrocement specimen

7.5.0 Test Setup

The experiment was part of research on the use of ferrocement for low-cost housing.
Specimens can test at the testing laboratory of the Civil Engineering Department, of any
University india. Each type of specimen was subjectedto loading as shown in Figures 10.

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 Figure 10.specimen was subjected to loading

8.0 PROPOSED SMALL HOUSE

Ferrocement, a material recommended by ACI 549R-97, is proposed for this house.
Ferrocement performs excellently due to its closely distributed reinforcement. This will be a
very economical option for temporary and permanent construction for the years to come.
Shortly after the earthquake this design was proposed, keeping in mind the cost efficiency,
availability of materials, quick time of fabrication and flexibility of extension and portability.

Figure 10. model, panel, joint, truss,footing and angles in ferrocement house

8.1.0 Features of Proposed House

The principal material for this house is ferrocement. It consists of ferrocement panels (3′-
6″x10′-6″each) placed side by side connected with steel plate fixtures using bolts (Figures
11,and 13). Ferrocement is selected because it is recommended by ACI 549R-97 as a very
good option for making small size houses. Furthermore, all the panels are lightweight, which
are easy to cast, transport and assemble. The system has been designed with the do it-yourself
concept in mind.

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 Figure 11. panel, bolt and joint specification

Table 5.Geomectrical properties

1 Size of House 10′-6″x 10′-6″[3.25m x 3.25m]

2 Panel Size 3′-6″x 10′-6″[1.10m x 3.25m]
3 Panel Thickness 1″[25mm]

Table 6. Steel
1 Angle Sections for L 2″x2″x1/8″[ L 51x51x3.2]
Truss, Purlins & Braces
2 Vertical Steel Ratio Required For 0.0012 (minimum
Panels
3 Horizontal Steel Ratio Required For 0.002 (minimum)
Panels

The vertical steel is 1/16″or 1.5mm wire @ 4″c/c & @ 3″c/c for horizontal steel. Such a small
spacing proves that thin wire mesh (grating) can be used for the wall panels, which is in fact
ferrocement.

8.1.1 Light Roofing System

One of the major causes of damage during earthquake was heavy roofs. Mud layer of one to
two feet was used to be placed on weak walls to avoid the severe cold during chilling winters.
During earthquake the weak vertical supports could not survive and came down with thick
layer of mud, burying everything under it. Lightweight roofs are better than heavier ones
because they:

 Generate lesser forces

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  Cause less damage if they fall.

Figure 12. truss for roof of house

The roof system of this proposed house consists of GI corrugated sheets with simply
supported lightweight trusses consisting of single angles (Figure 10). Every truss is strongly
coupled with panels by bolted steel fixtures. Braces connecting bottom cords of consecutive
trusses and the purlins ensure the space truss behaviour. Wooden trusses, which have been in
common use, are deliberately avoided as they are comparatively heavier and cause more
damage to life and property in case of collapse.

8.1.2 Joint Details

Most of the masonry and frame structures failed from the joints therefore special attention is
paid on joint details. The steel fixtures shown in Figure 13 will be used to make strong joints.

Figure 13. Steel fixtures

8.1.3 Foundations
Total service load reaction is 1.73 kips [7.69 kN] which yields a foundation size of 11″x
11″[280mm x 280mm] for a net allowable bearing capacity of one tons/ft 2 [100 kPa]
Foundation is proposed as 12″x 12″[300mm x 300mm] pre-cast ferrocement block with

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6″[150mm] total thickness (Figure 14). It has a 3” [75mm] deep grove to accommodate
ferrocement panels. Foundation depth is proposed as 2ft [600mm]. The connection between
foundation blocks and panels is developed by bolted angle section both at inner and outer
side. Blocks are so sized that a single person can easily lift and transport it to the required
place.

Figure 14. foundation of ferrocement house

8.1.4 Openings

Doors can be located at any desired position. It is just a matter of removing one panel and the
door opening is ready. Panels with windows and ventilators can also be cast but it is
recommended to have ventilators in roof.

8.2.0 Tentative Cost

Table 7.The tentative cost of structural elements of proposed house.

Serial Item Name Unit No. Unit Rate Total Cost

1 Cement Bag 15 350/- 5250/-

2 Sand ft3 45 20/- 900/-
3 Steel Wire Mesh ft2 800 8/- 6400/-
4 Angle Sections kg 145 60/- 8700/-
Total 21250/-

40% additional for connections and labour 8200/-

Grand Total 29450/-

It can be confidently said that cost will not cross rupees 30,000/-, which means it is rupees
275/- per square foot. The cost can also be quoted as rupees 2,850/- per foot length with a
width of 10′-6″[3.25m]. As stated previously, this structure can be easily extended so the

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approximate cost for any size can be easily calculated.

Figure 15. Contruction of ferrocement small house

8.3.0 Flexibility of Extension
Flexibility of extension and ease of alteration are two of the important features. Although this
house is proposed as a single room but the design has flexibility to add kitchen, bathroom and
stores etc. Adding more and more panels at the suitable location makes the extension very
simple. This small unit can be extended to build a field hospital, combined residence,
messing facility and a warehouse etc.

SINGLE ROOM FERROCEMENT HOUSE

Figure 14. Architectural view of single room ferrocement house

DOUBLE ROOM FERROCEMENT HOUSE

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 Figure 16 Architectural view of Double room+corridor house

FERROCEMENT HOUSE WITH ALL FECILITIES

Figure 17. plan of house

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 Figure 18. Elevation of house

9.0 ADVANTAGES & DISADVANTAGES OF FERROCEMENT

9.1.0 Advantages
 Less use of cement and steel for any given section compared with RCC with a
corresponding reduction in self weight.
 A major reduction in cost expenses compared to RCC
 An easy manufacturing process requiring only semi-skilled labour
 A simplified and cheaper installation practice compared to RCC
 The technique requires neither a scaffolding, a shuttering, a concrete mixer or a
vibrator
 They have a high degree of impermeability and resistance to cracking
 They require little or no maintenance
 They are economical compared to components built with steel, concrete, or brick
walls.

9.2.0 Disadvantages
 The need of a casting space and working area to prefabricate the elements and cure
them. This may be difficult or expensive especially in an urban setting.
 The need for a control to ensure quality products
 The need for a proper applied curing method, usually overlooked in any building
construction activities

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  If the elements are not manufactured on the site they will have to be transported
which may add to the cost. Care should be taken not to damage the elements during
transportation

10.0 OTHER USES OF FERROCEMENT COMPONENT

 Small capacity water tanks
 Cupboard slabs
 Roof & wall elements
 Shuttering for concrete construction
 Service core units
 Toilet component
 Benches, Furnitures, Dining & other tables
 Sofa sets, book store units etc.
 Biogas holders
 Boats and water troughs

11.0 CONCLUSION
Ferrocement products are an ideal substitute for wood and they can be extensively used in
various components of a housing like door, Roofing etc.Indian Experiences have shown that
construction cost could be reduced by about 20to 40% if ferrocement products are used in
place of conventional wood or R.C.C.Components. Developing countries where mass social
housing projects are being taken up the use of ferrocement components would go a long way
in helping them to build houses at economical cost and also at a faster rate.

REFERENCES
[1] www.SeminarsTopics.com
[2] www.hud.gov/accessed 10th Feb. 2007
[3] www.forintek.ca/accessed 12th Feb. 2007
[4] State-of-the-Art Report on Ferrocement ACI 549R-97, ACI Committee 549, American
Concrete Institute, Farmington Hills, MI, USA, (1997), 15-35.
[5] Ferrocement: Applications in Developing Countries/ NATIONAL ACADEMY OF
SCIENCE /Washington, D.C. • February 1973

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