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FERROCRETE - MATERIAL AND CONSTRUCTION METHODS

Ferrocrete is a type of reinforced concrete that uses closely spaced wire mesh or small diameter rods infiltrated with mortar. It has high density and durability to withstand various climates. Ferrocrete structures are lighter than regular reinforced concrete and do not require formwork. Some applications of ferrocrete include roofing, water tanks, bridges, and precast building components. Ferrocrete is constructed by first making a wire mesh framework, applying mortar that is worked into the mesh, and compacting it. This produces a strong, lightweight material suitable for many construction applications.

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FERROCRETE MATERIAL AND CONSTRUCTION METHOD
Ferrocrete - Ferrocrete 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 • synthetic compound composed of a mix of metallic alloys, ceramic polymers and stone • has high density and ability to stand for thousands of years once set in a wide variety of climates and environmental factors • concrete and iron that was molecularly bonded to produce a substance with exceptional resistance to wear and tear Ferrocement - The major advantages of ferrocement construction are: • the structures are thin and light, • can be easily precast • are amenable to repairs in case of local damage.
History – • Ferrocement is a relatively new material. • It was first used in France, in the middle of the 19th century, for the construction of a rowing boat. • Its use in building construction began in the middle of the 20th century in Italy. • Although its application in a large number of fields has rapidly increased all over the world, the state-of-the-art of Ferrocement is still in its infancy, as its long-term performance is still not known.
Sr. No. RCC FERROCRETE 1 Minimum thickness 100 mm Minimum thickness 25 mm 2 Course Aggregate is Present Rich portland cement mortar with Fine Aggregate 3 Reinforcement consisting of larger dia bars and more widely spaced as compared to Ferrocrete Greater percentage of reinforcement, comprising closely spaced small diameter wires and wire mesh, distributed uniformly throughout the cross- section 4 Structures are heavier than Ferrocrete Structures are lighter than RCC 5 Without formwork construction is not possible Can be constructed without formwork Difference between RCC and Ferrocrete
Applications Ferrocrete is recommended to meet the following requirements: • To produce high early strength in a wide variety of concretes, mortars and grouts. • To facilitate the early demoulding, handling and use of all types of precast concrete products. • To reduce formwork striking times. • To help maintain normal concrete production during cold weather. • To resist fire up to 750 ̊ C for a period of 48 hours or even more • To resist rust, rot or blow down in storms. • To apply in broad range
Advantages - • similar to or less weighty than a fiber reinforced plastic (fiberglass), aluminum, or steel framework • Less strength and lesser durability than standard RCC construction • mechanically overloaded, it will tend to fold instead of crack or rupture • 10 to 25% of the weight of a comparable construction made of bricks • Sleeker sections make it more aesthetically pleasing • Can be given in any shape, so organic shapes are possible Disadvantage – constructions is the labor intensive
Construction Method • The first step is to prepare the skeletal framework onto which the wire mesh is fixed with a thin tie wire (or in some cases, by welding). A minimum of two layers of wire mesh is required, and depending on the design, up to 12 layers have been used (with a maximum of 5 layers per cm of thickness).
Construction Method • The sand, cement and additives are carefully proportioned by weighing, mixed dry and then with water. Hand mixing is usually satisfactory, but mechanical mixing produces more uniform mixes, reduces manual effort and saves time. The mix must be workable, but as dry as possible, for greater final strength and to ensure that it retains its form and position between application and hardening.
Construction Method • After checking the stability of the framework and wire mesh reinforcement, the mortar is applied either by hand or with a trowel, and thoroughly worked into the mesh to close all voids. This can be done in a single application, that is, finishing both sides before initial set takes place. For this two people are needed to work simultaneously on both sides.
Construction Method • Thicker structures can be done in two stages, that is, plastering to half thickness from one side, allowing it to cure for two weeks, after which the other surface is completed. • Compaction is achieved by beating the mortar with a trowel or flat piece of wood. • Care must be taken not to leave any reinforcement exposed on the surface, the minimum mortar cover is 1.5 mm. • Each stage of plastering should be done without interruption, preferably in dry weather or under cover, and protected from the sun and wind. As in concrete construction, ferrocement should be moist cured for at least 14 days.
Use of Ferrocrete Technology 1. Ferrocrete Rafters and Purlins Based on ancient timber technology, modular Ferrocrete rafters & purlins are designed as a Logical replacement for factory made systems. The structure of the ferrocrete channel with simple modifications was made into a more viable, efficient and appropriate building material, used in conjunction with MCR tiles. • Durable • easy to manage • easy to store • Size can be controlled depending on the depth. • Resistant.
2. Ferrocement Building Ferrocement Building like floors, roofs and walls for residential places and office buildings. These are fabricated using ferrocement columns, beam & panel systems that helps reduction in consumption of cement and steel. Furthermore, these require almost no shuttering cost and have longer functioning life. The weight of a ferrocement building is 50% less than that of a RCC building.
3. Ferrocement Ducts Ferrocement ducts are suitable for circulation of cool or hot air and are structurally strong. Besides, these are capable of resisting environment damages and are superior than most of the conventional ones. These ducts also require supports at large intervals and are highly cost effective 4. Ferrocement Plated RCC structures Ferrocement Plated RCC Structure are a heterogeneous material with voids and capillaries. These are filled with water causing spalling of concrete crack formations. Furthermore, these reduces and obstructs the water moisture, air polluted gases to enter cracks and cause expansion & corrosion of reinforcement. • Designed as cracked section • Density about 2500 Kgs/M3 • Vibration with needles mostly leave some porosity between two pokes that means honeycombing • Voids and capillary formation is regarded to be normal in concrete • When concrete cracks are minute, then these can be sealed using autogenous healing
5. Ferrocement Water Storage Tanks Ferrocement Water Storage Tanks are constructed using ferrocement plates of 25 mm – 30mm thick. The structures are as strong as steel plates and are completely waterproof. Moreover, these types of tanks are highly resistant against earthquake & wind and are have high durability. Following are some of the features of these tanks: • Sturdy construct • Weight of the tower less by about 50% of R.C.C. • Life time Durability • Economical
6. Foot Bridges We offer foot over bridge that is used for crossing road, rail track or any place on foot. These bridges are fabricated with supporting columns, stairs, roof etc, as per requirement. 7. Manhole Covers Manhole Covers that are superior in quality and durability as compared to the conventional ones. Heavy duty as well as light weight covers are makes them ideal for busy places.
8. Horizontal And Vertical Extension Of RCC Buildings Horizontal extension of building with ferrocement technology is most convenient upto overhang of 1. 2 mtrs. Or more depending upon available strength of columns and beams on the periphery of the building. The extension is provided using the precast ferrocement beams, slabs, panels manufactured on machinery set up duly anchored to the building at floor level. The anchoring is done by using innovative indigenous method. The precast cantilever beams as well as beams at the edge are manufactured on machinery set up in the form of ‘u’ incorporated with the reinforcement for the beams. The joints between the precast beams and the building are duly connected by wiremesh lapping and welding and matrix applications. After this plane vibrated concrete poured in the hollow of beam.
9. Kitchen Cabinate Wall Cupboards that are highly acclaimed for their beautiful designs and sturdy construction. These cupboards are provided with or without shutters for storage of office records, factory material and other such similar things. Besides, these wall cupboards are also ideal for domestic purposes 10. Water Proofing Ferrocement Membrane Waterproofing is a structural treatment • cannot be punctured • resists wear and tear • is permanent with nil / negligible maintenance • solution to chronic leakages • It is unique
11. (Rain) water Harvesting using Ferrocement Technology • Drain Precast 2.4-3.00 Mtrs. long space saving • Precasting on machinery set up under controlled conditions • Any cross section • Fast construction – More faster with crane • Least execution time • Perforated precast cover –easily removable for thorough cleaning • No manholes • Long perforated cover Ferrocement tanks for storage 25-30 mm walls bottom and top Space saving Any capacity • Less space occupation • With Filtration Boring arrangement
12. Roofs The ferrocement roof consists panels size 1.5mtrs.x1.2mtrs. approximately and ferrocement portal and purlins replacing AC sheets and structurals steel trusses and purlins. Unlike AC sheet Metal, FRP roof all the ferrocement panels are joined monolithically. There will be no nuts and bolt arrangement as in the case of AC sheet Metal, FRP roofs. But ferrocement panels shall be connected to the purlins and portal by welding and in-situ vibrated cement matrix application. Or Ferrocement mega tiles of size 1.5 x 1.2 mtr. or more are laid just like Mangalore tiles with most effective interlocking arrangement to prevent rain water entry below. There will be least heat transfer as compared to AC sheets etc. The space below the roof shall be neat and clean since the steel trusses are eliminated. There will be far better storage space below without obstruction.
The ferrocement roof is superior as compared to A.C. sheets roof and metal sheets as below: - • Ferrocement can be monolith, jointless roof eliminating trusses and purlins nuts and bolts and joints as in the case of AC sheet/ Metal sheets roof. • Ferrocement roof shall transfer much less heat as compared to AC sheet/ Metal sheets roof. It can be fully insulated against heat transfer. Jointless ferrocement roof prevent humidity transfer inside. • Since structural trusses, purlins are eliminated space there is more storage space. Since ferrocement roof is monolith, there is no phenomenon such as cracking as in the case of AC sheet/ Metal sheets roof and leakage of rainwater and corrosion of nuts and bolts, therefore, least maintenance operations. Soffit of ferrocement roofs is neat and clean as compared to AC sheet/ Metal sheets roof since there are no steel trusses or tubular trusses. • In the long run ferrocement roof are very economical. • The performance of gutters and valleys is superior. Because these are integral with roof. • The life of tubular truss roof is much less in view of earlier loss of strength due to corrosion. • Wooden trusses purlins require replacement off and on. In ferrocement roof, no replacement is necessary.
13. Swimming Pool Construction Swimming Pools are specially designed for residential as well as commercial uses. These are available in varied shapes, colors, sizes & designs and provided with stereos, water pumps & other controls. 14. Vehicular Bridge Construction Vehicular Bridges from are ideal for transportation and public works applications as local crews using on-hand equipment can typically place the superstructure in one day – reducing costs, equipment time and road closure time.
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