INTRODUCTION
In 1943 pier luigi nervi tested and presented in his
paper, a new structural elements, an extremely thin
plate of concrete made of layers of small diameter
wire mesh and cement mortar with sand used as
the binder.
WHAT IS FERRO CEMENT ?
“Ferro cement is a type of wall reinforced
thin concrete, commonly of
constructed
cement mortar, reinforced with closely hydraulic
spaced layers
of continuous and relatively small size wire mesh.
The mesh may be made of metallic or other suitable
materials.”
Mortar provides the mass and wire mesh imparts tensile
strength and ductility.
When building Ferro-cement structures the sand/cement
mortar is applied to the reinforcing wire with a trowel,
never poured like common concrete work. Often a form is
used to provide the desired shape.
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.
TYPICAL CROSS SECTION OF FERROCEMENT
TECHNIQUES OF MANUFACTURES
Hand plastering
semi-mechanised process
Centrifuging and Guniting
MATERIALS USED IN FERRO CEMENT
Cement mortar mix
Skeleton steel
Steel mesh reinforcement or Fibre-reinforced polymeric
meshes
CEMENT MORTAR MIX
ordinary Portland cement and fine aggregate matrix
is used
The matrix constitutes 95% cement mortar & 5%
wire mesh of the composite.
FA (sand), occupies 60 to 75% of the volume of
the mortar
Plasticizers and other admixtures are used
MIX PROPORTIONS
Sand: cement ratio (by mass) 1.5 to 2.5
Water: cement ratio (by mass) 0.35 to
0.60
SAND
confirming to zone-I or Zone-II
free from impurities
WATER
Free from salts and organic impurities
Minimum to achieve desired workability
pH equal or greater than 7
SKELETON STEEL
It support the steel wire mesh
3 to 8 mm steel rods are used
Thickness varies from 6-20mm according to loading
condition
⚫ Generally mild steel or Fe 415 or Fe 500 bars are used
⚫ Spacing 7.5cm to 12m
Used to impart structural strength in case of boats, barges
etc.
Reinforcement should be free from dust, rust and
other impurities.
STEEL MESH REINFORCEMENT
Consists of galvanized steel wires of diameter 0.5 to 1.5
mm, spaced at 6 to 20mm centre to centre
Welded wire mesh has hexagonal or rectangular
openings
Expanded-metal lath is also used Made from carbon,
glass etc.
Chicken wire mesh
PROPERTIES OF FERRO CEMENT
It is very durable, cheap and versatile material.
Low w/c ratio produces impermeable structures.
Less shrinkage, and low weight.
High tensile strength and stiffness.
Better impact and punching shear resistance.
Undergo large deformation before cracking or high
deflection.
ADVANTAGES OF FERRO-CEMENT
It is highly versatile and can be formed into almost any
shape for a wide range of uses
20% savings on materials and cost
Suitability for pre-casting
Flexibility in cutting, drilling and jointing
Very appropriate for developing countries; labor intensive
Good fire resistance
Good impermeability
Low maintenance costs
Thin elements and light structures, reduction in self
weight & Its simple techniques require a
minimum of skilled labor
Reduction in expensive form work so economy &
speed can
be achieved
Only a few simple hand tools are needed to build
any structures
Structures are highly waterproof & Higher strength
to weight ratio than R.C.C
DISADVANTAGES OF FERRO-CEMENT
Low shear strength
Low ductility
Susceptibility to stress rupture failure
It can be punctured by collision with pointed objects.
Corrosion of the reinforcing material due to
the incomplete coverage of metal by mortar.
It is difficult to fasten to ferrocement with bolt,
screw, welding and nail etc.
Large no of labours required
Tying rods and mesh together is especially tedious
and time consuming.
APPLICATIONS OF FERRO CEMENT
1. Marine Applications
Boats, fishing vessels, barges, cargo tugs, flotation buoys
Key criteria for marine applications: light
weight, impact resistance, thickness and water
tightness
2. Water supply and sanitation
Water tanks, sedimentation tanks, swimming pool
linings,
well casings, septic tanks etc.
3. Agricultural
Grain storage bins, silos, canal linings, pipes, shells for fish
4. Residential Buildings
Houses, community centers, precast housing elements,
corrugated roofing sheets, wall panels etc.
5. Rural Energy
Biogas digesters, biogas holders, incinerators, panels for
solar energy collectors etc.
6. Miscellaneous uses
Mobile homes
Kiosks
Wind tunnel
Silos and bins
Bus shelters
pedestrian bridges
soil stabilization
chemical resistant treatment
Precast ferrocement structures
Boats, fishing vessels, barges, cargo tugs
THANK
YOU
