FERROCEMENT AND
ITS APPLICATIONS
Dr. M. Lakshmipathy
Prof.,
Dept. of Civil Engg/SRMIST
1
INDEX
[Link]. CONTENT SLIDE NO.
1. DEFINITION 3
2. FERROCEMENT TECHNOLOGY 11
3. ILLUSTRATION OF FERROCEMENT 24
TECHNOLOGY FOR CONSTRUCTING A
WATER TANK
4. USE OF GUNITE IN FERROCEMENT 39
TECHNOLOGY
5. CONSTRUCTION PROCESS OF MONOLITHIC 41
DOME/ECO SHELL
6. CONSTRUCTION OF A GARAGE WITH 48
FERROCEMENT
7. CONSTRUCTION OF SPECIAL STRUCTURES 55
LIKE STORM SHELTER, FALLOUT SHELTER,
ROOT CELLAR
8. FERROCEMENT SEPTIC TANKS 60
9. EARTHQUAKE RESISTANT BUILDINGS 62
10. FERROCEMENT AS LAVA CRETE 81
11. EXAMPLES OF FERROCEMENT USES 85
12. ADVANTAGES OF FERROCEMENT 98
13. APPLICATIONS 106
14. FERROCEMENT FOR REPAIR & 107
REHABILITATION
2
DEFINITION
Ferrocement is a super reinforced concrete. It
differs from conventional concrete in that there is a
higher ratio of steel to cement mortar. By altering
the cement/steel ratio to make ferrocement we
actually produce a material, which exhibits
properties, superior to either steel or cement
separately. Ferrocement has many of the properties
of steel and yet it will not rust. Although it looks and
feels like concrete it can flex without cracking.
3
Ferrocement is defined as a thin-wall
reinforced concrete with closely spaced
layers of continuous and relatively small
diameter mesh. The mesh may be made
of a metallic or other suitable material.
4
Ferrocement is both a method and a material
used in building or sculpture with cement,
sand, water and wire or mesh material - often
called the thin shell. Thin shell ferrocement
offers strength and economy and has a broad
range of applications which include home
building, creating sculptures, or building
boats and ships.
5
Ferrocement is, basically, the old
wire and plaster technique from the
time of Michelangelo Buonarroti
and Leonardo de Vinci, with
modern materials.
6
EXAMPLES
7
EXAMPLES
8
EXAMPLES
9
EXAMPLES
10
FERROCEMENT TECHNOLOGY
Example ferrocement section
11
FERROCEMENT TECHNOLOGY
Notice in the above graphic example
that there are two layers of welded
wire with a grid of reinforcing steel
bars (rebar) between them. Further
back is a darker area which depicts an
outer layer of metal lath or 1/2 inch
square welded wire. The finer layer
holds wet plaster in place and provides
significant strength. All these
materials are obtained from a store
which supplies materials to concrete
workers. 12
MATERIALS FOR FERROCEMENT
1. The reinforcing wire 5. Cement
2. Wire netting 6. Water
3. The cement mortar 7. Mixing
4. Sand 8. Curing
13
MATERIALS FOR FERROCEMENT
1. The reinforcing wire
It is important to get a good distribution of wire
mesh throughout the cement mortar to limit
cracking. Wire meshes come in a wide variety of
types, diameters, stiffnesses, and strengths. For
large tanks, welded meshes made from the larger
diameters of wire (above 4mm) welded at 100mm
to 200mm 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. 14
MATERIALS FOR FERROCEMENT
2. Wire netting
Wire netting, often called ‘chicken
wire’, is very useful for distributing
loads through the mortar and into
the larger diameter reinforcing
wires. It is easily moulded to form
spherically shaped surfaces, such
as arched roofs to tanks.
15
MATERIALS FOR FERROCEMENT
3. 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.
16
MATERIALS FOR FERROCEMENT
4. Sand
Clean, dry sand should be used. It should be well-graded, comprising
particles of different sizes. The importance of good, clean, well
graded sand, cannot be over emphasized if one is to make the high
grade impervious mortar required for structural applications.
The sand will be of a silicious nature and conform to the grading
envelope shown in Fig. The sand is not to contain sulphates, pyrites,
or other chemically active substances in such amounts that the mix is
harmed. If sea sand is used, it is to be washed free of any saline
compositions. (It is always preferable to use non-saline river sand.)
The sand should not contain loose clay or clay which adheres or
covers the sand grains. The sand is not to contain humic acid or
organic materials in quantities that may be detrimental. Preferably,
the sand should be 'sharp' and not contain non-crystalline minerals.
17
MATERIALS FOR FERROCEMENT
4. Sand grading chart
18
MATERIALS FOR FERROCEMENT
4. Sand grading chart
19
MATERIALS FOR FERROCEMENT
5. Cement
Cement should have been
recently manufactured and have
been protected from water
vapour during storage and
transport
20
MATERIALS FOR FERROCEMENT
6. 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. To achieve the
desired ratio, a bucket can be used to accurately measure out the
proportions of sand and cement. (Note that when sand from a
stockpile is damp it has a greater volume than when it is dry). As
cement 'bulks', it is preferable to use a full bag of known 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 litres of water to each 50kg bag of cement.
21
MATERIALS FOR FERROCEMENT
7. Mixing
It is preferable to use a concrete mixer. Where this is not possible, mix
the right ratios of sand and cement on a hard, clean surface until the
mixture is of uniform colour. Cast a mixing slab if necessary, or use a
portable mixing trough to prevent loss of cement and to prevent soil
contaminating the mortar.
Add only sufficient water to make the mortar ‘workable’. If the mortar
is too stiff because too little water has been added it will be hard to
compact; it will have a poor bond to the reinforcement; and it will not
be held in place by adhesion to the formwork. If the mortar is too wet
it will produce a weak and permeable tank. Water should never be
visible in the mixed mortar, even when it is left undisturbed in a pile.
Mixed mortar should be used immediately. Extra water should never
be added to soften the mortar once it has started to set. Cover or
shade the mixed mortar in hot weather and turn the pile over
regularly. 22
MATERIALS FOR FERROCEMENT
8. Curing
Once the mortar has set, keep it damp for
at least two weeks and preferably longer.
This curing is important for the proper
gaining of strength and the prevention of
cracking. It can be assisted by wetting the
surfaces and covering them with polythene
sheeting or wet sacking. It will still be
necessary to periodically wet the surfaces
before they can be allowed to dry.
23
ILLUSTRATION OF FERROCEMENT
TECHNOLOGY FOR CONSTRUCTING A
WATER TANK
24
ILLUSTRATION OF FERROCEMENT
TECHNOLOGY FOR CONSTRUCTING A
WATER TANK
25
ILLUSTRATION OF FERROCEMENT
TECHNOLOGY FOR CONSTRUCTING A
WATER TANK
26
ILLUSTRATION OF FERROCEMENT
TECHNOLOGY FOR CONSTRUCTING A
WATER TANK
27
ILLUSTRATION OF FERROCEMENT
TECHNOLOGY FOR CONSTRUCTING A
WATER TANK
28
ILLUSTRATION OF FERROCEMENT
TECHNOLOGY FOR CONSTRUCTING A
WATER TANK
29
ILLUSTRATION OF FERROCEMENT
TECHNOLOGY FOR CONSTRUCTING A
WATER TANK
30
ILLUSTRATION OF FERROCEMENT
TECHNOLOGY FOR CONSTRUCTING A
WATER TANK
31
ILLUSTRATION OF FERROCEMENT
TECHNOLOGY FOR CONSTRUCTING A
WATER TANK
32
FAIRING OUT & SMOOTHING
FERROCEMENT FOR CURVED
CONCRETE SURFACES
Trowel smoothing can slow down some types of
cement finishing, especially curved and unbacked surfaces.
Rollers can speed the job up. Here are some readily available
methods for using rollers to get faired out smooth results
quicker with ferrocement and curved concrete. It has been
found that paint style rollers with foam surface can give smooth
results quickly. Furthermore the rolling action compacts the
cement well. Hard rollers are well proven for flat concrete slabs
but lightweight paint rollers work best for ferrocement. Rollers
need modification. The trouble with unmodified paint rollers is
with absorbent material normally supplied and also the
weakness of the core.
33
FAIRING OUT & SMOOTHING
FERROCEMENT FOR CURVED
CONCRETE SURFACES
Different types of Rollers
34
FAIRING OUT & SMOOTHING
FERROCEMENT FOR CURVED
CONCRETE SURFACES
Different types of Rollers
35
FAIRING OUT & SMOOTHING
FERROCEMENT FOR CURVED
CONCRETE SURFACES
Giant Fly swattter
36
FAIRING OUT & SMOOTHING
FERROCEMENT FOR CURVED
CONCRETE SURFACES
Light weight nylon netting with
pencil point openings (Tulle)
37
FAIRING OUT & SMOOTHING
FERROCEMENT FOR CURVED
CONCRETE SURFACES
Fabric "ceiling"
38
USE OF GUNITE IN
FERROCEMENT TECHNOLOGY
Gunite, or Shotcrete as it is sometimes
called, refers to the process by which
concrete is pumped through a hose
and is sprayed as it exits from a
nozzle. This type of construction
allows the concrete to follow irregular
shapes and makes possible the
shaping of the material as it hardens.
It is the preferred technique for the
shaping of swimming pools, ponds or
even caves and buildings.
39
FERROCEMENT SHAPES
Combinations Of shell roofing
40
Construction process of
Monolithic Dome/Eco shell
The Monolithic Dome is a super-
insulated, steel reinforced concrete
structure used for homes, schools,
gymnasiums, bulk storage facilities,
churches, offices, and many other
uses.
41
Construction process of Monolithic
Dome/Eco shell
A Monolithic Dome starts as a concrete ring
foundation, reinforced with steel rebar. For
smaller domes, an integrated floor and ring
foundation may be used. Vertical steel bars
embedded in the ring beam footing are later
attached to the steel reinforcing of the dome
itself. The Airform, fabricated to a proper shape
and size, is attached to the concrete base. Using
fans, the Airform is inflated - creating the shape
of the dome.
42
Construction process of Monolithic
Dome/Eco shell
The Airform is both the form for
construction of the dome and the
outer roof membrane of the shell
when it is finished. The inflator fans
run throughout the construction of
the dome shell.
43
Construction process of Monolithic
Dome/Eco shell
Approximately three inches(75mm) of
polyurethane foam insulation is applied to the
interior surface of the Airform.
Steel reinforcing bars, or rebar, is attached
to the foam using special "hooks" embedded
in the foam. The rebar is placed in a specially
engineered layout of hoop (horizontal) and
vertical steel rebar.
44
Construction process of Monolithic
Dome/Eco shell
Shotcrete, a special spray mix of concrete, is
sprayed onto the interior surface of the
polyurethane foam, embedding the rebar.
After three inches of shotcrete is applied, the
Monolithic Dome is a steel reinforced,
concrete structure.
45
Monolithic Dome/Eco shell
Benefits
The Monolithic Dome is a permanent
structure which is energy efficient, cost
effective, disaster resistant and attractive.
Monolithic Domes have real strength.
They can withstand the force of a
tornado, hurricane or earthquake. They
cannot burn, rot or be eaten by bugs.
46
Monolithic Dome/Eco shell
Benefits
The Monolithic Dome is energy efficient. It will
usually save fifty percent on heating and cooling
costs compared to a comparable conventional
building.
47
CONSTRUCTION OF A
GARAGE WITH
FERROCEMENT
A closer view of the combination of vertical rebar,
horizontal wire and first layer of hexagonal mesh
48
CONSTRUCTION OF A
GARAGE WITH
FERROCEMENT
The outside is almost completely plastered, with only a portion of the front arch
remaining. The inside has been partially plastered on both sides.
49
CONSTRUCTION OF A
GARAGE WITH
FERROCEMENT
Fully plastered inside and out. The curved shape of the East wall
as it widens out at the rear portion of the structure can be seen in this view
50
CONSTRUCTION OF A
GARAGE WITH
FERROCEMENT
The edges of the wall surfaces were too small and sharply
rounded to plaster with a trowel. A gloved hand worked well
to smear the plaster into the edges of the mesh and lath and around the rebar
51
CONSTRUCTION OF A
GARAGE WITH
FERROCEMENT
To shape the curve of the roof and support the roofing metal properly,
flexible battens were screwed in place across the stringers
52
CONSTRUCTION OF A
GARAGE WITH
FERROCEMENT
Finished Garage
53
CONSTRUCTION OF A
GARAGE WITH
FERROCEMENT
Finished Garage
54
USE OF FERROCEMENT IN THE CONSTRUCTION OF
SPECIAL STRUCTURES LIKE STORM SHELTER,
FALLOUT SHELTER, ROOT CELLAR
13' diameter ferro-cement cellar can be used with the 24' diameter conduit
truss to produce a larger ferro-cement structure.
55
USE OF FERROCEMENT IN THE CONSTRUCTION OF
SPECIAL STRUCTURES LIKE STORM SHELTER,
FALLOUT SHELTER, ROOT CELLAR
This design is based on a conduit geodesic
truss acting as a form upon which a multi-layered
chicken wire covering is wired. This wire mesh then
being plastered with a sand-cement mix. The dome
shell will rest on a soft footing allowing the dome to
settle which in turns allows the compacted clay
overburden to act as an earth arch. To provide extra
radiation and over blast protection, the arched entry
must have a 90* turn and you must install a blast
valve to keep your ear drums from rupturing during
a nuclear blast.
56
USE OF FERROCEMENT IN THE CONSTRUCTION OF
SPECIAL STRUCTURES LIKE STORM SHELTER,
FALLOUT SHELTER, ROOT CELLAR
13' Conduit Truss with Mesh
57
USE OF FERROCEMENT IN THE CONSTRUCTION OF
SPECIAL STRUCTURES LIKE STORM SHELTER,
FALLOUT SHELTER, ROOT CELLAR
Emergency exit
This emergency exit hatch
is located at the rear of the
dome. It is to be used in
case of the structure is
used as a fallout shelter.
The extra entryway lets
the inhabitants set up a
direct air flow through the
shelter to prevent
claustrophobic conditions.
58
USE OF FERROCEMENT IN THE CONSTRUCTION OF
SPECIAL STRUCTURES LIKE STORM SHELTER,
FALLOUT SHELTER, ROOT CELLAR
Sand-Cement Mix being applied to Mesh
Backfill of Dome Structure
59
USE OF FERROCEMENT IN THE
CONSTRUCTION OF SEPTIC TANKS
60
USE OF FERROCEMENT IN THE
CONSTRUCTION OF SEPTIC TANKS
1000 and 1250 gallon tanks with H20 traffic rated covers.
These tanks can be buried in parking lots without the need for
an additional concrete slab over them.
61
FERROCEMENT IN THE CONSTRUCTION OF
EARTHQUAKE RESISTANT BUILDINGS
After the 2004 Indian Ocean earthquake
and the 2005 Kashmir earthquake, there has
been interest in the Indian subcontinent to
explore earthquake resistant construction
techniques suited to local conditions.
Ferrocement is being proposed as a suitable
alternative. Its proponents cite the many
advantages when compared to brickwork
masonry.
62
FERROCEMENT ROOFING
CHANNEL
Commonly called channels they are produced on
specially designed vibrating tables and profiled moulds. The
production system is uniquely tailored to provide special end
details, consistent shape and thickness; all crucial for high
performance the channels made with an optimized proportion
of cement, sand and water. Have a very high density, are
impervious to penetration of water and provide high structural
strength. Ferrocement roofing channels produced on
mechanised equipment can be used for intermediate floor
applications as well. Ferrocement roofing technology offers a
viable alternative to conventional flat roofing systems such as
reinforced cement concrete. Reinforced brick cement. Sand
stone, etc. In both rural and urban areas in the country.
63
FERROCEMENT ROOFING
CHANNEL
PRODUCT
Ferrocement roofing channels have a uniform segmental profile; they are
2.5 cm thick and 83 cm wide maximum length of mechanically produced
channels can be 6 metres. Longer spans for roofing can be built with
intermediate supports.
Ferrocement roofing channels are manufactured using a fixed proportion of
cement,sand and water to give high strength mortar that is reinforced with
a layer of galvanized iron chicken wire mesh of 22 gauge and Tor steel
bars of 8-12 mm diameter provided in the bottom nibs of the channel.
Ferrocement roofing channels can be safely transported after a curing
period of 14 days.
64
FERROCEMENT ROOFING
CHANNEL
PRODUCTION PROCESS
Ferrocement roofing channels are prefabricated elements. The
mechanized system of production uses a vibrating table and
profiled steel shell moulds the production yard consists of a
vibrating table positioned under a gantry system 65mts in
width the gantry is fitted with a chain and a pulley system for
ease of handling of shell moulds. A production team consisting
of 2 masons, 6 semi-skilled workers and a supervisor can
produce up to 5 channels of 4.6 mts length each in 8 hours
operation.
65
FERROCEMENT ROOFING
CHANNEL
FERROCEMENT CHANNELS PRODUCTION YARD
INSTALLATION
Ferrocement roofing channels are simply placed in a series,
next to each other resting on opposite walls of a structure. The
valley between channels are then filled with a plain cement
concrete. Over which a layer of bitumen is spread to ensure
water tightness. A lean concrete of 2.5 cm thickness or mud
phuska with brick tiles can be laid to make a flat surface and
provide thermal insulation.
66
FERROCEMENT ROOFING
CHANNEL
APPLICATION
Ferrocement roofing channels, offer unmatched speed of
construction and can be used for :
o Residences
o Primary schools, and other community buildings
o Porticos, verandahs and garages
o Industrial sheds, Workshops and godowns
o Farm houses and semi-covered structures
67
TECHNICAL SPECIFICATIONS
OF FERROCEMENT CHANNELS
PARAMETERS DESCRIPTION
Shape and size of Clear bay length 750 roofing channel
mm, total bay length 830 mm, rise of arch 290 mm, shell
thickness 25 mm. Weight of channel 50 kg per meter
length. Mortar composition 1 part cement : 3 parts fine
aggregates. Load carrying capacity 350 kg/sqmt. for
simple roof and 870 kg/sqmt. For intermediate floor.
Water absorption Less than 5% by weight of channel
68
TECHNICAL SPECIFICATIONS
OF FERROCEMENT CHANNELS
69
FERROCEMENT CHANNELS
70
FERROCEMENT CHANNELS
71
FERROCEMENT CHANNELS
72
FERROCEMENT CHANNELS
73
FERROCEMENT CHANNELS
74
FERROCEMENT CHANNELS
75
FERROCEMENT CHANNELS
76
FERROCEMENT CHANNELS
77
EXAMPLES OF FERROCEMENT
BUILDINGS
78
EXAMPLES OF FERROCEMENT
BUILDINGS
79
EXAMPLES OF FERROCEMENT
BUILDINGS
80
FERROCEMENT AS LAVA CRETE
When it is required to construct a pool deck that
blended with the backyard, after some research and
lots of experimenting a technique that allows to
duplicate the look of lava. Basically, latex molds
were made from actual lava flows on an island.
Stamping the impression from the mold into a
special concrete mix.
81
FERROCEMENT AS LAVA CRETE
Different views of pool deck
82
FERROCEMENT AS LAVA CRETE
Precast lava pavers can be cast into any shape and then be set
like tiles.
83
FERROCEMENT AS LAVA CRETE
Lava crete used for blending with surroundings
Before: After:
84
EXAMPLES OF FERROCEMENT USES
EXAMPLE OF WATER TANK
85
EXAMPLES OF FERROCEMENT USES
EXAMPLE FOR AQUACULTURE
86
EXAMPLES OF FERROCEMENT USES
EXAMPLE FOR AQUACULTURE
87
EXAMPLES OF FERROCEMENT USES
15000 Gallon water tank
Constructed in 1970. Photo taken in 2001. The tank is in service from 1970.
88
AESTHETIC USE OF FERROCEMENT
A FERROCEMENT BENCH
A good mix for the cement:
in a wheelbarrow, add:
5 or 6 shovels sand
1 shovel Masonary cement
1/2 shovel Portland Cement
89
AESTHETIC USE OF FERROCEMENT
90
AESTHETIC USE OF FERROCEMENT
91
AESTHETIC USE OF FERROCEMENT
92
AESTHETIC USE OF FERROCEMENT
WICKER CHAIR
93
AESTHETIC USE OF FERROCEMENT
FERROCEMENT MULTIPURPOSE TUB
94
AESTHETIC USE OF FERROCEMENT
THE CREATION OF EAGLE WITH STAND TO
BLEND WITH THE SURROUNDINGS
95
AESTHETIC USE OF FERROCEMENT
THE CREATION OF EAGLE WITH STAND TO
BLEND WITH THE SURROUNDINGS
96
AESTHETIC USE OF FERROCEMENT
THE CREATION OF EAGLE WITH STAND TO
BLEND WITH THE SURROUNDINGS
97
ADVANTAGES OF FERROCEMENT
Advantages of Ferrocement with conventional
RCC
It is cheaper in constructions and lighter than
RCC.
Its Strength to weight ratio higher than RCC.
It has less thermal conductivity as compared to
RCC.
It is thin and more aesthetic.
98
ADVANTAGES OF FERROCEMENT
Advantages of Ferrocement buildings with
Earthquake resistance
The weight of a Ferrocement building is about 25% of
an equivalent structure built with conventional 23cm
brickwork, and only 10% when compared to a building
made out of stone.
The building is entirely a box construction with rigid
frames along all three axes.
The building is resting on the ground and is not
embedded in the ground, so there is no need for an
excavation.
99
ADVANTAGES OF FERROCEMENT
Advantages of Ferrocement buildings with
Earthquake resistance
Thus, there is no mechanism to transfer the seismic loads
or ground vibrations to the building. However, there is a
frictional force between the base blocks and the ground,
and assuming that the friction coefficient does not
exceed 0.4, it can be very safely presumed that only 40%
of the seismic loads are transferred to the building.
Moreover, as the self load of the building is only 25%
compared to the conventional brick masonry building,
the seismic loading on ferrocement building would be
only 10% of a conventional brick building.
100
ADVANTAGES OF FERROCEMENT
Advantages of Ferrocement buildings with
Earthquake resistance
The advantage conferred by the two factors cited
above can be illustrated by examining the scenario
if the building experiences a strong earthquake of
intensity 7.5 on the Richter scale
The effective seismic loading on the Ferrocement
building is only 10%, therefore the effective intensity
of the tremors would be comparable to an earthquake
of 6.5 – a huge reduction.
The building weighs only a quarter of a brick building,
therefore the force experienced by the Ferrocement
building for the same earthquake would be 25% of the
conventional building. Thus the effective earthquake
intensity would be reduced even further to 5.9.
101
ADVANTAGES OF FERROCEMENT
Advantages of Ferrocement buildings with
Earthquake resistance
Ferrocement buildings also have the advantage of
‘’Windscreen Effect’’ – i.e. the material does not
disintegrate upon impact. Ferrocement walls and roofs,
being reinforced with steel mesh, do not move and fall
from their location, even when damaged by an
earthquake. This factor nullifies the major cause of
casualties in any earthquake.
Debris removal is a major task after an earthquake and
often takes lot of time and hinders relief and rescue
efforts. Ferrocement buildings are very easy to remove,
even when damaged. Ferrocement walls and roofs are
joined together by the steel mesh reinforcement as one
large chunk, which can be easily moved by a crane or a
tractor. 102
ADVANTAGES OF FERROCEMENT
Advantages of Ferrocement buildings with
Earthquake resistance
The material required for construction is lightweight
and results in major savings on transportation costs.
The major construction component is coarse sand,
which can usually be sources locally.
The speed of construction is much faster than
brickwork masonry.
103
ADVANTAGES OF FERROCEMENT
Advantages of Ferrocement buildings with
Earthquake resistance
The material required for construction is lightweight
and results in major savings on transportation costs.
The major construction component is coarse sand,
which can usually be sources locally.
The speed of construction is much faster than
brickwork masonry.
104
ADVANTAGES OF FERROCEMENT
Advantages of Ferrocement buildings with
Earthquake resistance
It is claimed that Ferrocement is eco-friendly when compared
to brickwork because bricks are usually made from topsoil
baked in coal-fired kilns. However, it should be kept in mind
that cement manufacturing is also known to cause high levels
of industrial pollution.
Ferrocement walls can be made to insulate against widely
varying temperatures in the tropical regions by employing a
method of construction where a layer of Thermocol is
sandwiched between two layers of Ferrocement. This
provides a thermally and acoustically insulated interior.
105
APPLICATIONS
Water tanks, sculpture, low-cost fire-proof houses,
Water jars, Boats, Septic tanks, Barges, barracks, and
ammunition storage structures (often
buried).strengthening, rehabilitation, brick masonry
columns, blendedcement, old buildings, retrofit
material.
Ferrocement dome structures are used for homes,
schools, gymnasiums, bulk storage facilities, churches,
offices, and many other uses.
106
FERROCEMENT FOR REPAIR &
REHABILITATION
OBJECTIVE OF REHABILITATION
To stop further damage and effective protection
To enhance the future performance
To restore the structural systems as close as
possible to its original status
To prevent collapses during natural disaster like
cyclone and earthquake
To prevent distress, remove defects and to
provide aesthetic appearance
107
FERROCEMENT – REPAIR &
REHABILITATION
STRENGTHENING MEASURES USED FOR MEMBERS
FAILED UNDER TORSION
Strengthening with mild steel plates
Strengthening by Jacketing technique
Strengthening by using Fiber reinforced concrete (FRC)
Epoxy treatment for crack repairs
Strengthening by Shot Crete
Strengthening of reinforced concrete beams using Ferro
cement
Strengthening of beams by grouting
Strengthening with steel reinforcement and
grouting 108
FERROCEMENT – REPAIR &
REHABILITATION
STRENGTHENING TECHNIQUES ADOPTED FOR
REHABILITATION IN THIS PRESENT INVISTIGATION
Epoxy Screed filling method
FRP jacketing
Ferro Cement Jacketing
Micro concrete jacketing
109
PREPARATION OF VIRGIN BEAMS
Virgin beams are well cleaned, as it has been exposed to nature for long
time.
The outer surface of the beam is well cleaned with steel brush, to remove
the coating given over the beam.
Cleaning for the beams has been done with a pressurized air and is allowed
to blow in to cracks so that to remove all the dust materials present inside it.
Crack filling agent used to fill up the cracks. For filling epoxy screed EP_LV
from cera chemicals has been used.
Epoxy screed consist of three parts such as, A-resin, B-hardener, C-filler all
the three has to be mixed in 1: 0.6: 12 ratio and is mixed well before it placed
Inside the cracks.
The screed has the capacity of self-flowing, so it has been used to fill.
110
PREPARATION OF VIRGIN BEAMS
Then the sides of the cracks are closed with plaster of
Paris, then the v-groove is made and then the cracks are
filled with screed
Again pressurized air is blown through the crack to fill up the crack
over its entire portion.
Then it is allowed to set for 7 days, by which it attains its
maximum strength of 80mpa.
The trial beam has taken its ultimate load again and this shows that
this type of crack filling can also be used as an repair material.
This type of crack filling is done for all the beams and then the
repair technique is adopted for the beams
111
PROCEDURE FOR APPLYING FRP
SHEETS
Initially general purpose resin is taken In a separate bowl
With the resin ,about 2% of accelerator is added and care should
be taken that it has to be stirred well to get the appropriate mix
To this, 2% of catalyst is added and stirred well. When the
catalyst is added its starts hardening, so based on the
requirement of time the amount of catalyst can be increased or
decreased.
Then the first coat of mix is applied over the beam and is
allowed to dry for 10 minutes.
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PROCEDURE FOR APPLYING FRP SHEETS
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PROCEDURE FOR APPLYING FRP SHEETS
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PROCEDURE FOR APPLYING FERROCEMENT
Bonding agent is applied over the beam, so that the
new concrete sets easily over the old.
Bonding agent is made of two parts of base and
accelerator which has to be mixed in 1 : 2 ratio.
Then the welded mesh is covered over the surface of
the beam along with chicken mesh.
Then the mix had been made with cement and sand
(1:1.5 to 1:3) with a w/c ratio of 0.3 to 0.4.
Plastering is done over the beam using the mix and
then allowed for curing.
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PROCEDURE FOR APPLYING FRP SHEETS
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PROCEDURE FOR APPLYING FRP SHEETS
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PROCEDURE FOR APPLYING FRP SHEETS
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PROCEDURE FOR APPLYING FRP SHEETS
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PROCEDURE FOR APPLYING MICRO CONCRETE
A special form work is made to cover all sides
of the beam with 25 mm cover.
Then the micro concrete mix is made with mix
ratio of 4 to 5 liters for 25 kg bag.
After Bonding agent is applied over the beam,
the mix is made and it is allowed to pour into
the form work.
After all sides are filled the top portion is also
finished and allowed to curing for seven days.
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PROCEDURE FOR APPLYING FRP SHEETS
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PROCEDURE FOR APPLYING FRP SHEETS
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PROCEDURE FOR APPLYING FRP SHEETS
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RESULTS
Results of the Ultimate Load after Rehabilitation by
Fiber Reinforced Plastic Jacketing Method
Ultimate Load Ultimate Load Ultimate load Ratio of Ratio of Efficiency
BEAM By Before After Ultimate Load Ultimate Load factor
Experimental Rehabilitation Rehabilitation Before After
Rehabilitation Rehabilitation
(t) (t) (t)
(1) (2) (3) (4) (3/2) (4/2) (4/3)
60A1 10.0 7.45 13.0 0.745 1.3 1.75
70A2 10.5 7.93 13.5 0.755 1.28 1.70
80A3 10.0 8.13 14.0 0.813 1.4 1.72
90A4 12.0 8.33 14.2 0.694 1.18 1.70
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RESULTS
Results of the Ultimate Load after Rehabilitation by
Ferro-Cement Jacketing Method
Ultimate Ultimate Ultimate Ratio of Ratio of
Load Load load Ultimate Ultimate
By Before After Load Load
BEAM Experiment Rehabilitati Rehabilitati Before After Efficiency
al on on Rehabilitati Rehabilitati factor
on on
(t) (t) (t)
(1)
(2) (3) (4) (3/2) (4/2) (4/3)
75B1 12 8.01 13.5 0.66 1.125 1.68
75B2 13 7.55 14.6 0.58 1.123 1.93
75B3 14 6.86 15 0.49 1.071 2.18
75B4 15 7.8 15.5 0.52 1.033 1.98
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RESULTS
Results of the Ultimate Load after Rehabilitation by
Micro Concrete Jacketing Method
Ultimate Load Ultimate Load Ultimate load
By Experimental Before After
BEAM Rehabilitation Rehabilitation
(t) (t) (t)
80C1 13.4 17.2 1.28
90C2 13.3 17.1 1.28
100C3 13.5 17.5 1.29
110C4 13.9 17.9 1.28
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RESULTS
Results of the Ultimate Load after Rehabilitation by
Epoxy Screed Filling Method
Ultimate Load Ultimate Load Ultimate load
By Experimental Before After
BEAM Rehabilitation Rehabilitation
(t)
(t) (t)
100D1 14 15.7 1.12
100D2 14.5 15.3 1.12
100D3 14.8 16.5 1.11
100D4 15.6 17.1 1.09
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REFERENCES
[Link]
[Link]
[Link]
[Link]/departments/cv
[Link]
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