Introduction

 Ferro-cement is a relatively new material consists of

wire meshes and cement mortar.
 Developed by P.L.Nervi, an Italian architect in 1940.
 Widely used due to the low self weight, lack of skilled
workers, no need of framework etc.
 Quality of ferro-cement works are assured because the
components are manufactured on machinery set up
and execution time at work site is less.
 Maintenance cost is low.
 Ferro-cement construction has come into widespread
use only in the last two decades.
 What is Ferro cement?
The name “Ferro cement” implies the combination
of:
Ferrous product+ cement
Reinforcement+ cement
Wire mesh or small diameter steel mesh+ cement
Ferro cement is a building material composed of a
relatively thin layer of concrete, covering such
reinforcing material as steel wire mesh.
Ferro cement consists of a cement-rich mortar
reinforced with layers of wire mesh, sometimes with
additional plain wire reinforcement for added strength.
Definition - According to ACI:
 “Ferro cement is a type of thin wall reinforced
concrete construction where usually hydraulic
cement is reinforced with layers of continuous and
relatively small diameter mesh. Mesh may be made
of metallic or other suitable materials.”
Ferro Cement
 Ferro cement is fireproof, earthquake safe and
does not rust, rot or blow down in storms. It is a
composite material which is used in building or
sculpture with cement, sand, water and wire or
mesh material - often called the thin shell, in
central north America.
Typical cross section of a
Ferro-cement structure
Typical cross section of a
Ferro-cement structure

5-25 mm

10-40 mm

Typical cross section of Ferro cement

Constituent Materials
 Cement
 Fine Aggregate
 Water
 Admixture
 Mortar Mix
 Reinforcing mesh
 Skeletal Steel
 Coating
Reinforcing Mesh
 Applications
 Buildings, Bus shelters, Bridge decks etc.
 Concrete road repair.
 Factory-built homes.
 Food and water storage containers.
 Irrigation structures.
 Creating sculptures.
 Repair of existing artifacts.
 Building boats and ships.
 Retaining walls and traffic-caution signboards.
 Compound-curved structures as domes, roofs, and
ship hulls.
 Ferro cement is used often because the
constructions made from it are better resistant
against earthquakes.
General Applications
In general in following purposes :
• Housing.
• Marine.
• Agricultural.
• Rural Energy.
• Anticorrosive Membrane Treatment.
• Miscellaneous.
Housing Applications
Water Supply
Marine Application
Agricultural
Water Tank
Rural Energy
Recent Applications
• Residential and Public Buildings.
• Industrial Structures.
• Agricultural structures.
• Transportation Structures.
Residential and Public Buildings
Industrial Structures
Agricultural Structures
Transportation Structures
Water Ride
Sun Sheds
 In Africa this bin is
often called the
“Ferrumba”, which
was taken from
the construction
material “Ferro
cement” and the
word “Rumba”, a
traditional storage
structure from
Northern Nigeria
Ferro cement bin (Ferrumba)
1 Stone base topped with cement mortar and
a spout to remove grain

2 Two pieces of
chicken wire on top
of the base to
reinforce the bottom
 3 Position wooden frame to shape
4 Cover the entire frame with chicken
the bin and fold up the chicken wire
wire leaving an opening at the top
 6 Make a lid, either
5 Plaster the outside with cement
cone-shaped or
mortar and when it is dry remove the
flat
wooden frame and plaster the inside

7 Use a bicycle tyre or a

piece of rubber to ensure
a tight fit
Walls
Cost Effectiveness of FC Structures
• The type of economic system.
• Type of applications.
• Relative cost of labour.
• Capital and local tradition of construction
procedure.
• Doesn’t need heavy plant or machinery.
• Low cost of construction materials.
 Construction
 The desired shape may be built from a multi-
layered construction of chicken wire.
 If needed reinforced with steel wire or steel bars.
 Over this finished framework, an appropriate
mixture of cement, sand and water is spread out.
 During hardening, the Ferro cement is kept moist,
to ensure the cement is able to set and harden.
Chicken Wire
Construction of a Septic tank

Elevation of a septic tank

 Economics
 They pay for themselves
 Houses pay for themselves with almost zero
maintenance and insurance requirements
 Water tanks pay for themselves by not being
replaced periodically.
 Advantages
 The low weight, maintenance costs and long
lifetime in comparison with steel constructions
 When a ferro cement sheet is mechanically
overloaded, it will tend to fold instead of crack or
rupture. The wire framework will hold the pieces
together, which in some applications (boat hull,
ceiling, roof) is an advantage.
 A Ferro cement construction has 10 to 25% of the
weight of a comparable construction made of
bricks
 Ease of construction
 Advantages (contd.)
 the building techniques are simple enough to be done by
unskilled labor, Ferro cement is an attractive
construction
method in areas where labor costs are low.

 Sand, cement, and water usually can be obtained locally,

and the cost of the reinforcing material (steel rods,
mesh, pipe, chicken wire, or expanded metal) can be
kept to a minimum.

 There is no need for the complicated formwork of

reinforced cement concrete (RCC) construction, or for
the welding needed for steel construction.

 Virtually everything can be done by hand, and no

expensive machinery is needed.
 Advantages (contd.)
 Ferro cement can be shaped in any form. It can be
formed into sections
less than 25 mm (1 inch) thick and assembled over a
light
framework.
 It is rot proof, impervious
to worms and borers, and watertight.
Advantages (contd.)
 Ferro cement is more versatile than RCC and can be
formed into
simple or compound curves.
 In Third World countries, Ferro cement is almost
always economically competitive with steel, wood, or
glass-fiber reinforced plastic (FRP) construction,
because steel and FRP are expensive and wood is
becoming more and more scarce.
 Because its use for
construction requires locally available materials and a
large
supply of hand labor, local jobs can be created.
 Disadvantages
 The labor intensive nature.
 Expensive for industrial application in the western
world but this "disadvantage" is the primary
advantage for those who compete with western
world corporations.
 Structures made of it can be punctured by forceful
collision with pointed objects.
 Disadvantages (contd.)
 In corrosive environments (for example, sea water)
it is often
observed that after several decades the reinforcing
materials
become corroded.
 It is nearly impossible to fasten objects to Ferro
cement with
bolts or screws, because drills usually break
against the lightly
covered reinforcing material. Fastening with nails
or by welding
is not possible.
 Ferro cement Water Tanks
 Ferro cement consists of a cement-rich mortar
reinforced with layers of wire mesh, sometimes with
additional plain wire reinforcement for added strength
 Tanks made of fibrocement are used in many countries
for the collection and storage of water for drinking,
washing, for animal use and irrigation.
Advantages of Ferro cement Water Tanks
over tanks made of concrete or brick
 They are usually cheaper to build and require less
skilled labor.
 They are able to withstand shock better, as Ferro
cement is more flexible.
 Smaller Ferro cement tanks are portable.

Ferro cement is only needed for tanks of capacities greater than

1000 liters. Below this size, cement mortar alone is strong
enough to withstand the applied loads.
 Forces on Ferrocement Structures
Compression Tends to press together or make more compact.
Crushing Presses between two opposing forces so as to
break, squeeze together, or put out of shape.
Flexing Bends or curves without breaking; perhaps under
its own weight.
Impact Hits with force, collision, or violent contact.
Shear Forces two contacting layers to slide upon each
other in opposite directions parallel to the plane
of their contact.
Tension Tends to cause extension or increase in length.
Formwork
 Wooden-Frame
 Pipe-Frame
 Trussed-Frame or Webbed-Frame
Simplified stages of construction of a
Ferro cement tank
Methods of construction
 Building tanks without using formwork
 Building tanks using temporary formwork
 Building tanks using permanent formwork
 Centrally produced tanks
 Figure:
Simplified
stages of
construction
of a Ferro
cement tank
Natural rock-shaped, stone colored, ferro-cement tank
Further points to consider
 The reinforcing wire: a good distribution of wire
mesh throughout the cement mortar to limit cracking.
For large tanks, welded meshes made from the larger
diameters of wire (above 4mm) welded at 100 mm to
200 mm spacing to a square or rectangular grid are
often used to provide a strong reinforcing frame,
which is then covered with smaller sizes of mesh or
netting.
Further points to consider
 Wire netting: Wire netting, often called ‘chicken
wire’, is very useful for distributing loads through the
mortar and into the larger diameter reinforcing wires.
 The cement mortar: Cement mortar is a mixture of
sand, cement, and water. The strength of the mortar
depends on these raw materials, the mix ratio, and the
workmanship of those who mix and use the mortar.
Further points to consider
 Sand: Clean, dry sand should be used. It should be
well-graded, comprising particles of different sizes.
 Cement: Cement should have been recently
manufactured and have been protected from water
vapor during storage and transport.
Further points to consider
 Water: The water used in the mix needs to be
clean, preferably of drinking-water quality.
 The cement: sand ratio: The usual ratio of
cement to dry sand is 1:3 by volume.
 The water: cement ratio: The ratio of water to
cement has an important effect on the final
strength of the mortar. A ratio of about 0.4:1 to
0.5:1 (ratio of water: cement by weight) is ideal,
which is equivalent to between 20 to 25 liters of
water to each 50 kg bag of cement.
Further points to consider
 Mixing: It is preferable to use a concrete mixer.
 Add only sufficient water to make the mortar
‘workable’.
 Mixed mortar should be used immediately.
 Compact the mortar well by pushing it hard
against the formwork.
 Curing : Once the mortar has set, keep it damp
for at least two weeks and preferably longer.
Finishing and painting
 After curing, the surface is rubbed down with
abrasive (carbide) stone to achieve a smooth
finish, and then rinsed thoroughly with fresh water
 Because well-made Ferro cement is impermeable
(waterproof), there should be no need for
painting.
 However, if painting is desired, the structure
should first be scrubbed with a 5% to 10% solution
of hydrochloric acid (HCl; protect eyes and skin),
flushed with clean, fresh water, and scrubbed
again with a weak solution of caustic soda (NaOH;
protect eyes and skin), after which it must be
rinsed again.
 The Ferro cement can then be sealed with a coat of
epoxy resin
Examples of construction
 Example 1: Storage Silos: Food and water
storage silos are constructed in Thailand using
Ferro cement with pipes or bamboo struts.
 Example 2: Irrigation Channels: Ferro
cement has been successfully used for farm
irrigation and water-control structures, including
water tanks, hydraulic gates, pipes, irrigation
channels, and channel linings.
Summary
 The advantages of Ferro cement construction are
as follows:

o It is highly versatile and can be formed into

almost any shape for a wide range of uses;

o Its simple techniques require a minimum of

skilled labor;

o The materials are relatively inexpensive, and can

usually be obtained locally;
Summary contd.
o Only a few simple hand tools are needed to build
uncomplicated structures;
o Repairs are usually easy and inexpensive;
o No upkeep is necessary;
o Structures are rot-, insect-, and rat-proof, and non-
flammable;
o Structures are highly waterproof, and give off no
odors in a moist environment;
o Structures have unobstructed interior room; and
o Structures are strong and have good impact
resistance.
Summary contd.
 The main disadvantage of Ferro cement for smaller
structures and boats is its high density (2400
kg/[m.sup.3], 150 pounds/cubic foot).
 The large amount of labor required for Ferro
cement construction is a disadvantage in countries
where the cost of unskilled or semi-skilled labor is
high.
 Tying the rods and mesh together is especially
tedious and time consuming.
 It is not possible to nail, screw, or weld to Ferro
cement.
Questions - ?
Never Give Up!