Concepts

of
Ferrocement
List of Points to be Addressed:

1. What is Ferrocement?
2. Materials Used in Ferrocement
3. Ferrocement Related Materials Testing
4. Applications of Ferrocement
5. Design Concept of Ferrocement
6. Ferrocement Related Products Innovated by HBRI
7. Advantages of Using Ferrocement Structural Elements
1. What is Ferrocement?

Ferrocement is a type of thin wall reinforced concrete construction, where usually a hydraulic
cement is reinforced with layers of continuous and relatively small diameter mesh. Mesh may
be made of metallic materials or other suitable materials.
 2. Materials Used in Ferrocement

The material used in ferrocement consists primarily of mortar made of Portland cement, water,
aggregate and the reinforcing mesh.

• Cement
• Aggregates
• Water
• Admixtures
• Mix Proportioning
• Reinforcement
• Wire Mesh
• Welded Wire Fabric
• Expanded Metal Mesh Reinforcement
• Bars, Wires and Prestressing Strands
• Discontinuous Fibers and Nonmetallic Reinforcement
Primary Materials used to Fabricate Ferrocement Product(s)
Types of Wire Meshes Used in the Fabrication of Ferrocement Items

Figure 1: Assumed Longitudinal and Transverse Directions of Reinforcement

 3. Ferrocement Related Materials Testing

• Test Requirement

Tests and observations that are commonly made during the design, construction, and subsequent service
life of concrete structures shall also be applicable to ferrocement structures. The test programme shall
include

(a) Tests on physical, chemical and mechanical properties of the ferrocement ingredients, such as water
purity, sieve analysis, mesh strength etc.,

(b) Control tests for fresh mortar mix, such as slump, air content etc.,

(c) Tests on the mechanical properties of the hardened ferrocement, such as bending, cracking and
fatigue strengths, permeability etc., and

(d) in-service condition tests, such as potential for corrosion, cracking, durability etc.
 Testing Methods

• Compressive strength and static modulus of elasticity of mortar

The compressive strength and static modulus of elasticity of the mortar used for the fabrication of
ferrocement shall be determined from 75 mm x 150 mm cylinders tested in accordance with ASTM
C39 and C469, respectively.

• Flexural strength of ferrocement

Ferrocement specimens shall be tested as a simply supported beam with third point loading.
Ferrocement (FC) Beam and Colum Tests inside HBRI Premise
• Tensile properties of the mesh reinforcement

Square or rectangular meshes may be tested directly in tension; hexagonal meshes and
expanded metal meshes shall be tested only while encapsulated in mortar.
For square and rectangular meshes, the yield strength, elastic modulus, and ultimate tensile
strength shall be obtained from direct tensile tests on samples of wires or flat coupons cut
from the mesh. The test shall be in accordance with the following guidelines :

(a) The test specimen shall be prepared by embedding both ends of a rectangular coupon of
mesh in mortar over a length at least equal to the width of the sample. The mortar
embedded ends shall serve as pads for gripping. The free (not embedded) portion of the
mesh shall represent the test sample.

(b) The width of the test sample shall be not less than six times the mesh opening or wire
spacing measured at right angles to the loading direction.

(c) The length of the test sample shall be not less than three times its width or 150 mm,
whichever is larger.

(d) Measurements of elongations (from which strains are to be computed) shall be recorded
over half the length of the mesh sample.
(e) Yield strain of mesh reinforcement shall be taken as the strain at the intersection of the best straight
line fit of the initial portion of the stress strain curve and the best straight line fit of the yielded portion
of the stress strain curve, as shown in the Figure provided in the next slide. The yield stress shall be taken
as the stress point on the original stress strain curve at the yield strain found above.

• Tensile Test of Ferrocement:

Direct tensile tests of ferrocement elements shall be made using rectangular specimens satisfying the
same minimum size requirement already discussed for the mesh reinforcement. The test specimens shall
be additionally reinforced at their ends for gripping. The middle half of the non-gripped (free) portion of
the test specimen shall be instrumented to record elongations. A plot of the load elongation curve up to
failure shall be used to estimate the effective modulus of the mesh system as well as its yield strength,
ultimate strength, and efficiency factor. The yield strain and corresponding stress shall be determined in
accordance with the procedure described previously.
Figure 2: Schematic description of mesh tensile test sample and corresponding stress-strain
curve
Tensile Strength Test of Mesh Reinforcement inside HBRI Laboratory
 4. Applications of Ferrocement

Two Major Utilizations of Ferrocement Technology are:

 Fabrication of Structural Elements (e.g. partition wall, window frames, door shutters,
precast roof elements, domestic water tanks, furniture, manhole covers, boats, etc.)

 Maintenance and Damage Repair of Reinforced Concrete Structures.

 5. Design Concept of Ferrocement

• Design Principles and Requirements:

 The analysis of a ferrocement cross-section subject to either bending, or to bending and axial load,
whether based on strength or working stresses, is similar to the analysis of a reinforced concrete
beam or column having several layers of steel.

 In the design of ferrocement structures, members shall be proportioned for adequate strength using
load factors and strength reduction factors applicable for RCC design.
Figure 3: Strain and force distribution at ultimate in a ferrocement section under
bending
• Strength Requirement:

 Ferrocement structures and structural members shall have a design strength at all sections
at least equal to the required strengths for the factored load and load combinations
stipulated in Chapter 1 of BNBC.

 General Design Requirements. Required strength (U) to resist dead load (D) and live load
(L) shall be determined in accordance with the provisions of Chapter 2 of BNBC.

 Design strength for the mesh reinforcement shall be based on the yield strength fy of the
reinforcement but shall not exceed 690 N/mm2.
6. Ferrocement Related Products by HBRI
Ferrocement (FC) Channel

 Centering & shuttering

materials can be eliminated
during construction
 Strong and durable
 Cost can be reduced up to 20%
compare to conventional
System
 Cost can be reduced in frame
and foundation due to less
dead load
 Quality control can be ensured
 Easily fabricable
Ferrocement Channel
Ferrocement Channel
Ferrocement Channel
Ferrocement Folded Plate

 Cost effective and

Durable
 Does not require
timber or bamboo
frames required for
C.G.I sheet roofing
 Quality Control can
be ensured
 Strong enough
against hail storm
Ferrocement Folded Plate
Ferrocement Folded Plate
L- Panel

 Centering & shuttering

Not require
 Cost effective and
durable
 Comfortable in summer
and winter compare to
C.I. sheet House.
 Rafter & purlin can be
eliminated
 Quality control can be
ensured
 It is strong enough
against hailstorm
L- Panel
Ferrocement (FC) Water Tank

 Less chance of pollution

 No rust Like GI tank
 Water remains comparatively cool
 Easy construction technology
 Durable and Cheaper cost
Type 01: FC Floating Emergency Shelter
FC Floating Emergency Shelter Characteristics:

• Location: Mongla Majhir Ghat, Jaiira, Shariatpur

The shape and size of the floating emergency shelter is given below:

• Octagon in shape
• Total floor area 1567 sft
• Consists of four classrooms of 166 sft each
• Teacher’s room of size 86 sft
• Disaster mitigation room of size 86 sft
• During disaster max capacity is 260 people at a time.
At fully loaded condition pontoon level will be 2 ft high from the water
surface
Type 02: Reusable Prefabricated House
Reusable Pre-fabricated House:

• Location: Aricha Ghat, Shibaloy, Manikganj.

• Suitable for flood affected people.
• Total floor area 625 sft.
• Single-storied, durable, and cost-effective model house
• Chemically treated natural roofing components
• During disaster, the non-structural components can be removed at a
suitable place.
• Imperishable structural parts will not be replaced
• These houses will be reusable after recess of floods
Type 03: Removable House
Removable Pre-fabricated House:

• Location: Fulchori, Gaibandha

• Suitable for river erosion victims.
• Single-storied, durable, and cost-effective model house
• During disaster, the non-structural as well as structural components
can be removed.
• Later on can be reconstructed at a suitable place
Type 04: Stilt House for Cyclone and Flood Affecting Areas
Stilt House:

• Location: Shyamnagor, Shatkhira

• Total floor area 558 sft.
• Single storey Nucleus house .
• This house was designed strong enough against collapse by good anchorage,
join details and concrete posts with individual pocket footing.
• Instead of normal attic, it has some extra height, and an attic floor made of
FC Channels.
 
 7. Advantages of Using Ferrocement Structural Elements

High corrosion resistance

High strength
Lower unit weight
Easy to handle
Good fatigue behavior

More heat resistant

Consume less building materials

Easily repairable and maintenance

cost is negligible

Adequately fire resistant and no risk of

damage due to stagnant flood water

Earthquake resistant, therefore the loss of

properties and life shall be less
Thank You