Ferrocrete 3o6d49

Ferrocement is a highly versatile form of mesh reinforced cement mortar that possesses unique quality of strength and serviceability. The major advantages of ferrocement construction are: the structures are thin and light, they can be easily precast and they are amenable to repairs in case of local damage. Ferrocrete is a super-strong building material that is composed of concrete and steel-like materials bonded together at the molecular level. Nearly every structure on most Imperial and New Republic worlds is built of this durable substance, and is the Star Wars equivalent of reinforced concrete.

Ferroconcrete, or ferrocrete, was a composite building material made from the combination of concrete and iron that was molecularly bonded to produce a substance with exceptional resistance to wear and tear. The material was used primarily in the construction of roads and walkways, but also for reinforced bunkers and building foundations. In the real world, the Latin word for "iron" was ferrum, leading to the chemical symbol for iron being "Fe" and ironsmiths being known as "ferriers."

Properties of Ferrocrete are:  Consumption of cement generally 500 to 750 kg per M³



  

Reinforcement : a) Wire mesh - woven : hexagonal, weided dia 0.5mm to 2.5mm, spacing 6mm to 75mm Consumption 350 - 500 kg per M³. b) Fibers - metallic, non-metallic - manmade & natural dia. 35g or 0.3 x 0.4mm. Consumption 1 - 3%. Cover to reinforcement - 2.5 mm to 5 mm - Cover to fibers - nil. Fine aggregate - particle size 400 micron to 3mm No coarse aggregate.

        

Generally no shuttering. ixtures are mostly used for workability, high strength, anti shrinkage, waterproofing and pollution resistance. Minimum dimension 10mm and maximum 60mm or so. Homogenous isotopic material at the initial stage. Fire resistant up to 750°C for a period of 48 hours or even more. Dead weight of Ferrocement frame structure is 175 kg to 275 kg per M³ Uncracked section material generally. Generally not affected by carbonation, chloride penetration, etc. Autogenous healing should take place Strength : 56.90 KN/ mm^2 Available sizes : 1050 mm X 500 mm X 45 mm

Thickness & Strength Thickness

Strength

Application

60mm 80mm 100mm 120mm

M-30 M-40 M-50 M-60

Light Light/Medium Heavy Duty Extra Heavy Duty

Following are the diffrent types of the paving blocks Unipaver

I Shape

Brick Shape

370/100 sqft

325/100 sqft

445/100 sqft

Applications Interlocking Concrete Paver Blocks of 60mm, 80mm & 100mm have applications in several solutions. The 60mm blocks are used for light traffic. 80mm are used for medium traffic and 100mm for heavy traffic roads. Various applications as per traffic conditions are suggested below.

Heavy Application : -

Toll plaza Bus depots Approaches to railway level crossings Road intersections City Streets Truck parking areas Industrial Floors Urban Sections of highways Road repairs during monsoon Container Depots Port landing areas and approach roads/ Airport approach roads - Roads in high altitude areas

Light Application : Medium Application : - Footpaths and sidewalks - Petrol Pumps - Cycle tracks - Residential streets - Rural roads through villages - Car parks - Highway rest areas/ food malls - Shopping malls/Shopping plazas

Reinforced and Non- Reinforced Precast Concrete Pipes : Pipes are manufactured by spinning process and automatic vertical vibrated casting process. Pipes from both processes comply with Indian Standards: 458 – 2003. Various t options also available: Spigot Socket ended, Flush t (Male/Female type), etc.

Various sizes and class available as below: Rounded Pipes

Half Rounded Pipes Diameter

Class

Diameter

NP2

150mm to 1200mm

150mm

NP3

150mm to 1600mm

250mm

NP4

150mm to 1600mm

350mm 400mm

Quality Check

 Sample checking of one block per batch done for confirming as per specifications.  Periodic testing of blocks done as per standard test parameters for Compressive strength & Density/weight  Blocks tested in laboratory also for all the test parameters periodically  All blocks are made of uniform thickness within (+/-) 3mm allowable tolerance as per IRC specification.  Variations in length and width of blocks i9s controlled in rigid moulds within 2-3mm to ensure uniform t width to avoid staggering effect during or after laying.

1.Precast concrete combines the advantages of off-site prefabrication with the inherent advantages of concrete. 2.Precast delivers significant cost savings by reducing formwork by up to 70% and reliance on wet trades by up to 90%. 3.The need for access scaffolding/shuttering can be reduced by anything up to 90% and site supervision by the main contractor is also greatly reduced. 4.Other advantages include reduced construction programmes, greater project control, greater accuracy and quality of finish and larger clear spans. 5.When making cost comparisons with alternative construction systems it is important to consider these savings and the superior quality and performance of precast.

Following are the diffrent types of Kerb stones Kerbstones Kerbstones

300mm X 450mm X 100mm

500mm X 400mm X 150mm

Kerbstones

500mm X 475mm X 150mm

Following are the diffrent types of Road Dividers Parabolic T-Shape

330mm x 750mm x 200/100mm

5 Kilometer Stone*

200mm x 150/400mm x 200mm

Guard Stone

200mm x 750mm x 200mm

1 Kilometer Stone*

Ferro - Cement by Ron Davis www.watermotor.net Ferro-Cement: One material for many uses If you are thinking about building a low-cost, long lasting water tank, a commercial fishing boat, a life-size model dinosaur, a semisubterranean house, or a retreat center in the remote desert, ferro-cement might just be your material of choice. It has been for others. Ferro-cement construction has been used successfully for all of these things. Other uses for ferro-cement are numerous: walls, floors, and roofs for underground structures, underground water tanks, built-inplace well liners, water control devices, canal lining, retaining walls, stairways built over adobe blocks, rain splash protection for adobe and rammed earth structures ---just to name a few. What is ferro-cement? It is a strong, versitile, low-cost, long-lasting building material made from a wire reinforced mixture of sand, water, and cement. A ferro-cement structure is usually 2-5 cm (3/4"-1 3/4") thick--- much thinner and lighter than poured concrete structures. Because it has wire reinforcing distributed throughout the structure, ferro-cement structures have much greater tensile strength and flexibility than ordinary concrete. When building ferro-cement structures the sand/cement mortar is applied to the reinforcing wire with a trowel, never poured like common concrete. Often a form is used to provide the desired shape.

Why would builders choose ferro-cement construction over other methods? In the case of the water tank it might be because it is being constructed in a remote location with the use of unskilled labor, and where materials must be carried in by hand. If suitable sand can be obtained locally, then only cement and common chicken wire would have to be brought in. A conventional poured concrete tank would require several times the volume of materials, as well as boards for the necessary form .

A ferro-cement hull fishing boat would use materials often easier to obtain locally than wood, and be longer lasting than a wooden hull, especially in tropical conditions. It would probably be faster to build, and use less specialized labor. The ferro-cement desert retreat center had the advantages of utilizing unskilled labor provided by the of the religious community, locally available materials suitable for desert conditions, and another beside---for religious reasons all structures at the retreat center had to be built in the form of a triangle. (honest!) This last requirement alone might have posed serious problems if conventional building materials had been used-but posed little difficulty with ferro-cement construction methods and materials.

The model dinosaur had to be made from a low-cost material which could be easily formed into a complex shape by hand, and would withstand severe outdoor weather conditions for many years. This illustrates the flexibility of ferro-cement as a building material. In each of these cases ferro-cement presented certain important advantages over other possible construction materials. Ferro-Cement Basics The strength of a ferro-cement structure depends on basically two things: 1. The quality of the sand/cement mortar mix.The sand must be clean and sharp. The cement must be fresh, and the mortar mix "dry"that is: well mixed using a minimum of water. The mortar should be used as soon as possible after mixing, especially in warm weather. 2. The quantity of reinforcing material, usually common "chicken wire". More wire results in a stronger structure. A high quality boat hull will require as many layers of wire as can be gotten into the thickness of the hull. On the other hand a water tank or a housing structure may only require two layers of wire in a 2.5 cm (1") thick structure to provide sufficient strength. I had been impressed 25 years ago when I spent a month at this retreat center by how well this material had stood up, for decades, in a harsh, desert environment. The shapes of the structures blend in well with the desert, and the coloring used was "natural". I recently checked, and found that this center was still functioning after perhaps 50 years. (See "Institute of Mentalphysics" on the Internet, for pictures.) I had first learned the basics of ferro-cement in India from a fellow building water tanks in rural Nepal, and soon after started building large water tanks myself in California. These tanks were built around a re-usable cylindrical form made from low-cost wall ing. The reinforcing wire was attached to the outside of the form.

I found that ferro-cement was an inspiring wonderful material for many creative uses-and in many cases the best material at any price. Problems There were just two problems when using a form for ferro-cement construction. One was that since the layers of woven reinforcing wire( chicken wire) were flat, they would lay together against the form, one atop the other. This made the wire hard to penetrate with a properly dry mortar mix. And this was also not the best distribution of reinforcing wire for maximum strength. Ideally the wire reinforcing ideally should be located near the surfaces of the ferro-cement structure. That is, one layer of wire is against the form, and the other layer near the outside surface. That means that there needed to be a way of holding the outside layer of wire away from the form while the mortar is being applied. Another problem was the difficulty in knowing how thick the mortar was being applied to the form. If a uniformly strong, professional looking structure was to be the result, the thickness of the mortar had to be controlled. Solution: Wavy Chicken Wire In order to deal with these problems I invented a simple material----chicken wire with small waves pressed into it. This simple material solved all the problems. I call it Ferro-Form Reinforcing Wire The waves can be of different sizes---the adjustable machine I built to produce this material presses waves ranging from 5-20 mm (0 .2 "-0.80 ") in height. The waves are about 33 mm (1.25") apart from crest to crest. In an ordinary application a form would have a layer of normal flat woven wire placed over it, a layer of wavy Ferro-Form wire placed over that, and finally another layer of flat chicken wire on top.

The Ferro-Form wire keeps the two layers of flat chicken wire separated, which allows the mortar to penetrate the reinforcing. And it also permits the person applying the mortar to know how thick it is being applied. Ferro-Form makes ferro-cement construction literally "child's play". The Ferro-Form machine can be adjusted to produce chicken wire with smaller waves. This allows more wire reinforcing to be used without producing an increase in the overall thickness of the structure. The patented, hand operated Ferro-Form machine is simple to build using commonly available materials. It will process a roll of ordinary chicken wire in less than five minutes. Plans for this machine cost $25 per set. If interested, or have any questions, write to us at [email protected]. Ron Davis, www.watermotor.net

Inbuilt Ferrocement Structural Formwork Thin section Formwork for slabs, beams, columns Manufactured on machinery set-up Reinforcemet of slabs, beams, columns incorporated in Formwork body If required, additional reinforcement can be provided Formwork to be left permanently in the structure Time saving by about 10-15% and Cost saving about 10% The wiremesh in the formwork makes the structures strong with no/negligible requirement for repairs in the life of the structure All inbuilt formwork for slabs, beams, columns of the building is well connected and monolith It makes the structure best earthquake and cyclone resistant with least damages The structure shall not require repairs almost for life time. The structure shall resist fire upto 750oC for 48 hours temperature and duration can be increased Ferrocement High Rise Buildings reduce cost by about 10% of R.C.C. reduce time of construction by about 10% of R.C.C.

eliminates formwork of columns, beams, slabs environment friendly inbuilt structural formwork is more durable, waterproof than R.C.C. do not require major repairs in its life time remain almost in tact during earthquake and cyclone can swing by a metre or so with no damage resist fire for almost 48 hours 750o C and can be made to resist higher temperatures. has less self-weight by about 50% of R.C.C. Ferrocement is a low self-weight construction Ferrocement scores over R.C.C Bond force on small section reinforcement is very high Resulting in delayed bond failure with delayed failure of flexures, shear and torsion Delayed crack formation till reaching near to yield High permissible strength quite near to yield

No collapse during earthquake duration of which hardly few seconds Only deformation that too may be at Richter scale 8 or so. Ferrocement structures remained Untouched during Earthquake at Richter scale 7.2 - 7.4 High degree of durability High degree of ductility It requires less strength development to carry its own low weight R.C.C. requires more strength to carry its own heavy self-weight It is economical Ferrocement is a low self wt. construction, reduction being about 50% vis-à-vis RCC Therefore Ferrocement structures are superior to R.C.C. structures. Ferrocement Structurals score over Steel Structurals There is no corrosion phenomena. Our Nation spends Rs.240,000 crores every year on corrosion Reinforcement of Ferrocement Structure is variable as per stress Development along length of structural member. Hence reduction of steel material. Steel structural has constant material content along its length Easy to manufacture

Economical in the long run Plates of plate girder and stiffeners incorporated during manufacture Reduction of mining of iron ore from mother earth Reduction of carbon dioxide generation at 1.5 ton per ton of steel production Energy saving It is economical Therefore Ferrocement structures are superior to steel structures Ferrocement Plates on R.C.C. surfaces eliminate Water-proofing deficiencies and Corrosion of reinforcement.

Lacunae of R.C.C. - I Cracking and Spalling • A heterogeneous material with voids and capillaries •

Designed as cracked section

•

Density about 2500 Kgs/M3

•

Vibration by needles leave some porosity between two pokes- means somewhat honeycombing

•

Voids and capillary formation is said to be

Virtues of Ferrocement - I No Cracking and Spalling • Ferrocement is isotropic material upto 40% of yield • Designed as isotropic material upto 40% of yield • Density about 2750 Kgs/M3 Therefore free of voids and capillary • Vibration on machinery set up- no honeycombing,no voids, no capillaries cast

normal in concrete. •

insitu vibrated,no possibility of honeycombing, voids, capillary since thin

Excess water than required for hydration

section

cause void, capillaries •

These voids and capillary filled with water cause spalling of concrete crack formations

•

Least energy absorbing material, easy collapse in earthquake

•

Carbonation phenomena cause spalling of Cracks wide and with large spacing and If cracks are minute, then sealed by autogenous healing

•

It is easy for water moistures, air polluted gases to enter cracks and cause expansion and corrosion of reinforcement

•

except human inadvertence • No / nominal excess water cause no voids and capillary being thoroughly vibrated • No voids, no capillary, no spalling wiremesh • High energy absorbing – does not collapse in earthquake may deform, better than steel

deep

•

No Void and capillary in Ferrocement

bind matrix very efficiently.

concrete •

•

Therefore RCC is never a waterproof material

• No carbonation phenomena since W.C. ratio are 0.35-0.38 • Crack very minute/nil and at close spacing and shallow • Crack if at all are very minute in microns and autogenous healing most effective • No entry of water moisture, polluted gases

In spite of several types of preventive treatment defects development may be reduced but definitely

since no void no capillary no cracks Ferrocement is always waterproof material There is no defect development for Ferrocement

persists

manufactured strictly as per specifications and workmanship except human inadvertence

Slip of

• Much delayed slip of

cementing matrix on coarse aggregate is beginning of compression failure

cementing paste over sand fine aggregate because of high specific surface and high bond strength– compression failure delayed. • Compression failure is

• When compression failure takes place rarely

delayed since cement matrix of high strength. No compression failure of sand particles

coarse aggregate is crushed

Lacunae of R.C.C. - II Corrosion of reinforcement

Virtues of Ferrocement - II No Corrosion of reinforcement

•

• No/nominal excess

Excess water in concrete around reinforcement cause of corrosion. The

water– no corrosion of wire reinforcement – no spalling • No corrosion of wire reinforcement; no cracks

same excess water in concrete also causes spalling in due course of time. • Corrosion of reinforcement takes place due to access of water, gases, moisture etc.

and porosity and no entry of water, gases etc. • During manufacture only nominal Layer of water film make brown coloration/ nil coloration since wires galvanized. • Such thing does not happen with Ferrocement • No/negligible rust, no force to crack matrix cover about 5mm thk. However superficial surface crazing in

through

fractions of microns with

cracks

no relation to crack

and porosity in concrete • During concreting the water starts corroding the reinforcement from the day

formation due to rust from reinforcement

one • Corrosion due to excess water around reinforcement cannot cause damage to concrete body behind the reinforcement • But the rust strong enough to cause cracks in the concrete cover which is 12mm to 30mm - 40 mm • Water, gases, moisture enter cracks and cause further corrosion

• No entry of water, gases etc although superficial surface crazing • No such phenomena

• This corrosion

• No collapse phenomena

adds to

but deformation under

widening of

severe conditions such as

cracks and

earthquake phenomena

further

higher than about 7.5

deterioration

Richter scale

all around reinforcement. • There is chain reaction leading to collapse if not attended

Lacunae of R.C.C. - III Structural aspects • This will be

Virtues of Ferrocement III Structural aspects • This will be covered LATER ON

covered LATER ON The Ferrocement plate arrangement on R.C.C. surfaces is a separate topic

Horizontal And Vertical Extension Of RCC Buildings It is most usual that extensions to the buildings are required to be carried out in view of necessity of more area requirement in the building. The limit of additional floors depends upon the strength of columns mainly. Sometimes columns are erected very near to the building and additional floors are provided. Horizontal extension of existing building adds to floor area at the same level which is required many times rather than one above the other. Normally this is provided by constructing columns near the existing columns and also farther as required and floor provided. Horizontal extension of about 1.2 mtrs. which has to be cantilever, is not feasible with R.C.C. and cannot be thought of in view of anchorage problem, high moments of cantilever beams and slabs and beam with wall load at the edge of extension. Extension activity to building cause nuisance to occupants such as sound, dust, traffic etc. Also open space around building is occupied by shuttering material, cement, sand site office etc. It can be said it is a great nuisance to the occupants. Vertical extension with ferrocement columns, beams, slabs is much convenient. It is possible to have more additional floors. Since ferrocement has much less self-weight about 50% as compared to RCC., ferrocement columns, beams are of small sections and ferrocement slabs are thin, say about 40 – 50mm thick. This is because ferrocement is much strong material. In view of small section reinforcement and very high bond strength development, permissible stresses in ferrocement are much high as compared to RCC. Therefore extension of building with ferrocement columns, beams, slabs can have more additional floors than that is possible with RCC. At extra expenditure of removing the existing load of brick work etc. from existing floor, it can be possible to have still more additional floors.

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, s 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 ts 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. Vertical and horizontal extension by Ferrocement Technology is more convenient and feasible since the selfweight of ferrocement element is quite low. Also since the ferrocement element such as beams, slabs are manufactured away from the site cause less inconvenience to the occupants of the building. The time of providing extension work to the building at site is reduced by about 50% since the activity of precasting is carried out at other locations.

FERROCEMENT WATER STORAGE TANKS

FERROCEMENT WATER TOWERS •

• Constructed using

Ferrocement plates 25 mm – 30 mm thick

Self weight of tank body on Tower is less by 50-60% against R.C.C.

•

Earthquake forces and wind forces reduce to

manufactured on machinery set up under controlled conditions

a large extent •

stronger than R.C.C.

• As strong as Steel plates • Totally Waterproof

•

• ts strong

•

• Constructed underground

Ferrocement tower frame does not require normal repairs for life time Ferrocement tower and tank will not collapse, may require nominal repairs even under worst

ground level terraces, Towers • Towers most efficient against earthquake and wind

Ferrocement tower frame more durable,

disasters •

Cost reduction by about 15- 20% as compared to R.C.C.

• Self Wt. of tower less by

about 50% of R.C.C. • Life time Durability. •

15 – 20% less cost vis-àvis R.C.C.

Ferrocement Water/Liquid Storage Tank

•

built with Ferrocement plates better than steel plates

•

No corrosion

•

No off and on anti-corrosive Treatment

•

Totally waterproof

•

Water tower best to conventional

•

Can be ed on Ferrocement beam, columns.

•

No plates/Stone slab s with beams required as in the case of plastic tanks

FERROCEMENT WATER STORAGE TANKS Ferrocement tanks have been giving excellent performance since more than two decades. Our Ferrocement Water Storage tanks are proven and unique. The Ferrocement water Tower tanks are most efficient from the point of earthquake and wind. The main reason is that self-weight of the Ferrocement water storage tank on the tower is less by more than 50% as compared to RCC. The surfaces of tank, have wire mesh immediately below. As such no repairs are required during its life time except rarely. The Ferrocement water storage tank consists of ferrocement plates of sizes about 1.2 x 1.1 mtrs. or so thickness about 20-30mm manufactured on machinery set up under controlled conditions. These are as strong as steel plates highly water proof and no phenomena of corrosion. No off and on painting is required as is for steel plate tanks. The water inside the tank shall remain more cool as compared to steel tank.

These tanks are giving excellent performance. These tanks should give excellent performance even more than 30 years as per our information. We can carry out tanks of several lakhs capacity underground as well as overhead on tower or at terrace level. We have installed hundreds of ferrocement water storage tanks

TANKS COMPARISON OF FERROCEMENT TANKS VISA-VIS PLASTIC TANKS Sr No. 1

PLASTIC TANKS

FERROCEMENT TANKS

Life of plastic tanks is about 12years Ferrocement tanks will last for about since plastic is subjected to 25/30 years and more since ferrocement considerable expansion and contraction is a structural water proof material due to day to day temperature variation. Plastic tanks will crack in due course of containing wire mesh reinforcement and time as we experience in our day to day can easily take the effect of day to day life.

and seasonal temperature.

2

It has been reported that the taste of

Water remains comparatively much cool

water stored in plastic tanks is annoying and hygienic and there is no bad taste or and uncomfortable. Water stored in

odour. These tanks can be insulated if

plastic tanks gets heated up and is

required.

uncomfortable for use in summer. 3

Plastic containers can be manufactured up to a maximum capacity of 20000 liters.

4

Ferrocement tanks can be manufactured up to any limit, say several Lakhs liters.

Plastic tanks have weak bottom and has Ferrocement tanks have strong bottoms to be ed by MS plate platform. In and are ed on ferrocement beam view of this rain water gets trapped in

frame work. There is no question of

between the surfaces of the

phenomena such as corrosion.

bottom. This will cause corrosion in due course of time. It will also not be possible to apply painting at these surfaces because the plastic tanks cannot be removed from its position off and on. Or plastic tanks are ed on RCC or cement concrete platform. 5

Plastic tanks cannot be put underground.

Ferrocement tanks of any capacity can be provided underground

6

7

Plastic can be attacked by rodents. To best of our knowledge plastic tanks have been banned in WD.

8

It is reported some times plastic tanks when empty are blown away in heavy

Ferrocement tanks cannot be attacked by rodents. Ferrocement tanks are being accepted more and more. This is not the case with Ferrocement Water Tanks.

wind or cyclone.

COMPARISON OF FERROCEMENT TANKS VISA-VIS M.S. TANKS Sr No

M.S. TANKS

1

Life of M.S. tanks is about 10 years for

2

3

FERROCEMENT TANKS Ferrocement tanks lasts for 30 years

4mm thick plates.Heavy repairs start

and more with negligible maintenance,

after about 6years life.

no painting, no repairs.

Water becomes hot in summer. Water becomes polluted with rust

Water becomes less hot and takes more time. There is no phenomenon of rust

formation and requires to be cleaned

formation. The tank is required to be

often.

cleaned only for removal of silt

deposition.

COMPARISON OF FERROCEMENT TANKS VISA-VIS R.C.C. TANKS. R.C.C. TANKS

Sr No 1

FERROCEMENT TANKS

Life of RCC tank is 30 to 40 years and Ferrocement tanks will last for about 25 it can require heavy repairs and

to 30 years and more, since

maintenance after about 10 to 15

ferrocement is a tructural waterproof

years.

material containing wire mesh reinforcement, and can easily take the effect of day-to-day and seasonal temperature.

2

RCC tanks require waterproofing treatment.

Ferrocement tanks themselves are waterproof and no waterproofing treatment is required.

3

Self-weight of RCC tanks is about 4 times that of Ferrocement tanks.

Ferrocement tanks are very much less in self- weight and can be shifted upto 5000 liters capacity.

4

RCC tanks create more earthquake and wind force.

5

Thickness of walls, bottoms, slab is comparative much more than

Ferrocement tanks create very less earthquake and wind force. Ferrocement tanks create very less earthquake and wind force.

ferrocement tanks. 6

To take load of 12.5 tons of water

To take load of 12.5 tons of water self-

self-load of RCC tank shall be about

load of Ferrocement tank shall be about

30-40 tons.

2.5tons only.

FERROCEMENT WATER TOWER VIS-A-VIS RCC WATER TOWER Sr Comparison No

FERROCEMENT WATER TOWER Self-weight of ferrocement

1

Self weight of RCC water tower

Self Weight water tower tank is about 60% tank is more than 250% that of less than that of RCC. Durability

Ferrocement being crack resistant material, it is very

2

Strength

ferrocement water tower tank. RCC is generally cracked section material. It is deteriorates after

much durable with no repairs

15-20 years. Therefore itrequires

requirement up to 50years.

early repairs.

Ferrocement has high strength 3

RCC WATER TOWER

to weight ratio.

RCC has much low strength to weight ratio as compared to ferrocement.

4

Foundation

Cost of foundation of

Cost of foundation is higher than

ferrocement water tower tank is that of ferrocement. Weak soil less than that of RCC.

requires costly foundation such as

Foundation of ferrocement

pilling or any other.

frame is convenient on weak soil. Pre-gunited Structures

The surface of beams, columns, floors, have wire mesh

the case of RCC frame. RCC

reinforcement layers

sections generally being cracked

immediately below, by about 5mm.The wire mesh

5

There is no such arrangement in

are vulnerable to atmospheric polluted gases entry. Therefore

reinforcement is of small dia and more prone to early deteriorations at close spacing. Therefore it

of reinforcements and spalling of

resists crack formation very

concrete.

efficiently. There are at least two layers of wire mesh. Ferrocement water tower tank 6 Waterproofing does not require any

Waterproofing of walls and floor has to be exclusively carried out.

waterproofing treatment. The roof of Ferrocement water tower tanks is very much 7

Roof

The soffit of RCC water tower gets deteriorated after 10-12years and

durable and the soffit does not

if not attended immediately, the

deteriorate as in the case of

whole slab has to be re-casted.

RCC. 8

Earthquake and wind

Ferrocement frame of water tower is very much ductile. The

In case of RCC water tower tank earthquake and wind forces are

resistance

earthquake and wind forces are very high. Because of very low because the self

comparatively very high self

weight of the ferrocement water weight. tower tank is very low. 9

Life Cycle Cost

Life Cycle cost of ferrocement

Life cycle cost of RCC frame is very

water tower tanks is very low as high. compared to RCC. Cost of ferrocement water tower Cost of RCC water tower tanks is

10

Cost

Ladders

tanks is about 15% less than

about 20% more than that of

that of RCC.

Ferrocement.

The ladders/ staircase for water tower tanks shall also be

11

The ladders of RCC water towers are generally made out of steel.

constructed out of ferrocement, These require regular which is more durable with less/nil maintenance.

maintenance. It may be required to be replaced if heavy deterioration.

Ferrocement Underground, Overhead & Ground Level Water Storage Tanks

Ferrocement

Ferrocement

Hexogen water

rectangular

storage tank

underground

ed on RCC Beams and

water storage tank

columns for CIDCO.

with Pump

Capacity 5000 liters

House for CIDCO. Capacity 35000 liters

Ferrocement

Ferrocement

Rectangular

Underground

Water storage tank

Cylindrical

ed on Ferrocement Beams capacity 5000 liters

water storage tank for TIFR. Capacity 50000 liters

Ferrocement Rectangular Water storage tank

Ferrocement Spherical water storage

ed on

tank e

Ferrocement Beams

d on RCC

capacity 5000 liters

columns and precast concrete Blocks for JNPT. Capacity 2000

Underground water storage tank size (3.6x2.4x1.5mtrs.ht.) . Selfweight of this tank is about 3.5 tonnes as compared to 12.5 tonnes of RCC. Thus very easy for handling. Such tanks on a tower shall reduce cost of tower

A ferrocement water tank could efficiently take onslaught of falling coconut tree with nominal damage in view of very highenergy

and very efficient to resist earthquake and wind. Only because of less self-weight, the tank was assembled on ground and than lowered into a pit.

absorbing capacity. The repair cost was a fraction of cost of the tank, which would require total replacement of it was plastic or steel tank.

Ferrocement Underground, Overhead & Ground Level Water Storage Tanks

Ferrocement Water Tank

Such type of are not

Such type of are not

required of Ferrocement Tanks

required of Ferrocement Tanks

REPAIRS, REHABILITATION AND RETRO-FITTING

REPAIRS, REHABILITATION, AND RETROFITTING BY FERROCEMENT

Ferrocement Cantilever can be planned to be Longer than R.C.C. Cantilever because of less Self-weight and high strength. These Canti- levers can take

•

Most effective as it is structural treatment

earthquakes and cyclones more efficiently than R.C.C.

• Vibration and wiremesh Reinforced

Ferrocement structures Highrise buildings Inbuilt Ferrocement Structural Formwork Ferrocement scores over R.C.C.

•

Layers make the mortar dense and

•

Ferrocement Balcony

score over Steel Structurals

crack resistant

•

much lighter than R.C.C.

Most durable

•

Best against earthquake and cyclones

•

Best replacement to crashed R.C.C. balcony

•

new balcony can be attached to entire building

•

No disturbance to the occupants

treatment even after one and a half decades •

Fire resistant upto o

750 C for 48 hours •

Ferrocement plated RCC structures Horizontal And Vertical Extension Of RCC Buildings Water StorageTanks Underground Overhead Tower

Can be made to resist high

Ferrocement structurals

Weather shed Chhajja attachment with

temperature •

Existing room area can be extended by a meter or so

•

Jacketing of column

Ferrocement plates • •

•

Prevention of

t with building totally waterproof

Retrofitting Waterproofing Mini structures

•

Integrates with building Corrosion resistance

and beams 40-50 mm thk.

Attachment by innovative anchoring system

Repairs, Rehabilitation

•

Brackets generally provided for conventional are eliminated

Earthquake resistance Disaster resistance

buckling of columns. Roofs

•

Crack formation along reinforcement even after repairs by other systems

•

Rainwater harvesting Elevation Pergola Cladding

shall not take place

Vehicular bridges

Research on repairs

Foot bridges

with Ferrocement Technology has proved that RCC improve in strength by 125% to

Irrigation Structures Swimming pools

300% as compared to original undamaged condition.

REPAIRS, REHABILITATION AND RETRO-FITTING Significance of Ferrocement repairs After, we in India, started manufacture of concrete in years 1930‟s, the negative aspect of concrete started showing after sometime as below:- Deterioration due to poor workmanship, particularly high water content and corrosion of reinforcement and R.C.C. Technology being new.

Ships, boats, barges, docks

- Leakages in concrete due to rain water as well as in water retaining structures This menace become conspicuous after construction works which became old about 20 to 30 years. We started realizing the importance of water cement ratio that only since about 40 years before and we have become very much conscious and now most of our engineers try their best to have Water cement ratio to the extent of its requirement. Even then, we did not stop production of concrete with water content comparatively more. It had been accepted that concrete is heterogeneous material and theory of reinforced concrete design is on the basis of cracked section below neutral axis. With this acceptance, scores of water proof additives and other ixtures contributing to the increase in strength, durability, workability and waterproof quality of concrete have come into market. Now it is a foregone conclusion that you cannot have best quality of concrete unless ixtures are used in its manufacture. Also many instruments for diagnosis for defective concrete such as porosity, lamination of cement matrix with course aggregate, corrosion of reinforcement, location of corroded reinforcement, strength of concrete etc. have come in the market in a very big way. Systematic method of inspection observations with measurements of the defects in concrete in a qualitative and also in quantitative manner have been developed and schemes / system of management of diagnosis analysis to maintain / to restore water proof quality and repairs to its original strength have been developed. All the above methods / system of water proofing, repairs and rehabilitation of structure costs lakhs of crores of Rupees to the nation. In order to save such expenditure, in-convenience, loss of time and energy CAN WE NOT PRODUCE A

CONCRETE FREE OF SUCH DEFECTS?

The quality of concrete can be improved to a large extent now. We are able to produce concrete of strength M100 or even sometimes M 200 with least reason for corrosion of reinforcement. Now a days corrosion of reinforcement is prevented by epoxy coating and galvanizing of reinforcement. Because of theory of reinforced concrete with provision of design of cracked section, the defects are bound to develop in due course of time which may be delayed. Prestressed concrete is the solon to a large extent with pretension structures. However there is possible corrosion in post tension structures due to errors in proper grouting of cables. In any case structures now should be better than before. Concrete is heterogeneous material. It has features to loose bond with aggregate and steel reinforcement at early stages. It can be said it is not possible for concrete structure to last for hundred years. Now it is the time when we should think of concrete which should not crack at all and there should be no extra water more than required for reaction with cement. And concrete should not crack at all when put under design loads. That means we must view or think about the theory of reinforced concrete that is a structural member is designed as cracked section cracking accepted below neutral axis. Or crack formation can be thought to be delayed. In other words crack width and minimum depths to stop entry of corroding forces upto reinforcement. Also the crack width should be so minute and depth should be so shallow that water be trapped in stopping it to travel below upto the bottom of the depth or reach reinforcement surface. The effect of atmospheric pollution or carbonation can be

minimized/eliminated by use of certain ixtures in the concrete.

Ferrocement Technology is the solution Under laboratory loads Ferrocement bends largely alongwith reinforcement without cracking. Under further loads, several cracks do take place, width being very negligible to few microns. Under very large loads only little wider cracks of low value less than 0.1mm take place. After this, structure will deform greatly but no collapse can take place. However on release of loads the cracks close. The deflection recovery has been found to be 97%. Sometimes it is said it has inbuilt property of prestress concrete to less extent In view of this significant feature of Ferrocement it is termed to have mechanism called „Crack arrest mechanism‟

Corrosion of Reinforcement The corrosion of reinforcement in Ferrocement is most insignificant. The water cement ratio is the least giving least extra water to react with wiremesh reinforcement. There may be corrosion of brown colouring with wiremesh reinforcements which is not strong enough to burst cement matrix. In view of evenly spread wiremesh reinforcement, the corrosion is the most negligible and can be said to be not at all causing any damage. We can say the minute corrosion is dormant in the case of Ferrocement. This is the feature of Ferrocement unless it is manufactured with inferior materials and inferior workmanship in slipshod

manner. In view of this and cement matrix being of superior quality, spalling / splitting will not take place.

We have been practicing Ferrocement Technology since more than 25 years by now. In our Ferrocement products, we maintain water cement ratio to be 0.35 to 0.4. We invariably vibrate our Ferrocement products either on machinery set up under controlled conditions or in- situ. In all our products to make it dense, we use ixtures to produce maximum strength and add many positive aspects to the materials. We use non- metallic fibers in the top of finished matrix. In view of such method of manufacture, we do not find any deterioration of our product and no problem so far as water proof quality of Ferrocement is concerned. In our Ferrocement products, there is no carbonation phenomena. We claim our method of manufacture is most meticulous with high quality and superior materials and workmanship. We are confident that our structures are bound to perform in a far superior manner.

Historically Ferrocement has proved to be durable and without corrosion as below:- A small Ferrocement boat constructed in 1887 was in operational condition till 1968 after which it was shifted to lounge of the Vereniging Nederlands Cement industries‟ office in Amsterdam.

- Several structures constructed by Mr. Pier Luigi Nervi during early 1940‟s in number of cities in Italy have been reported to be in good condition. - During 9th International Symposium, Prof. Khan A.M. in a t paper alongwith Prof. Rafeeqi S.F.A. and - During 9th International Symposium, Prof. Khan A.M. in a t paper alongwith Prof. Rafeeqi S.F.A. and

Prof.

Lodi S.H. from Karachi, Pakistan presented a

paper “Performance of Park Structure made by

Ferrocement”.

They carried out

experiment to study condition of a water storage tanks from the point of durability

view of

and corrosion constructed by students of Engineering college in about

1993. He has

concluded that the water

material has sustained the atmospheric

tank structure made up of Ferrocement condition satisfactorily. No

significant

corrosion effect of wiremesh was visible.

In our experience with Ferrocement Technology at international level having attended all the Nine International Symposiums we have not come across any structure that has collapsed or is damaged due to corrosion.

As a matter of fact, United Nations Industrial Development Organisation (UNIDO) have published a book in 1972 „Ferrocement boats‟ and recommended the use of Ferrocement Technology at the earliest.

Food and Agricultural Organisation (FAO) of UNO (United Nations Organisation) organized international conference, Ferrocement fishing boats in the year 1972. It has recommended adopting Ferrocement Technology for fishing vessels in view of Ferrocement being a sound technology.

Similarly, Royal Institute of Naval Architecture (RINA, UK) and National academy of Sciences of USA have recommended in about 1972 use of Ferrocement technology as early and as fast as possible.

For the present international Ferrocement society, Bangkok, founded in 1991 and Committee 549 of USA and certain publications by RILEM, Paris, have been guiding by publishing documents for the design and construction of Ferrocement structures.

REPAIRS

Sr.

Ferrocement Repairs And Rehabilitation

Visa-vis Polymers/Guniting Repairs And Rehabilitation

Ferrocement Repairs and

Polymers/Guniting Repairs and

No. 1

Rehabilitation System Ferrocement repairs and rehabilitation system can increase strength of columns, beams, and

Rehabilitation Treatment Polymer/guniting repairs and rehabilitation system cannot contribute to increase in strength of

slabs by 30% to 15% or even more. structures. 2

Ferrocement repairs and rehabilitation system contributes to prevention of cracks formation.

Polymer/guniting repairs and rehabilitation treatment can contribute little bit to prevention of cracks formation.

3

Ferrocement repairs and

Polymer/guniting repairs and

rehabilitation system material does

rehabilitation treatment material can

not allow penetration of

prevent little bit entry of water and

water, atmospheric gases etc.

atmospheric gases in due course of time.

4

Ferrocement repairs and

Polymer treatment looses strength

rehabilitation treatment resist fire up heavily at about 50-60oC and to 750oC and higher for long period

guniting at about 200oC.

of 48 hours and more. 5

Ferrocement repairs and

Polymer/guniting repairs and

rehabilitation treatment is waterproof rehabilitation treatment is not

waterproof. 6

Ferrocement chhajas can totally

Polymer/ guniting system can not

replace deteriorated crashed RCC

replace crashed/ collapse RCC

chhajas with dead load reduction.

chhaja. New RCC chhaja can not be

Even where there is no RCC chhaja-

attached to building. At the most

new ferrocement chhaja can be

new weather shed with A.C. sheet/

attached to building.

FRP/GI sheet can be attached but no assured waterproof at the junction.

7

8

Jacketing of columns, beams, with

Jacketing of columns, beams, is

ferrocement is about 30mm thick

7.5cm thick, occupying large space;

and adds strength.

may/may not add strength.

Ferrocement repairs and rehabilitation system is assured and

Polymer/ guniting is generally not assured and guaranteed treatment.

guaranteed. 9

Ferrocement repairs and

RCC sagging deteriorated slab

rehabilitation can conveniently repair repairs is cumbersome, time RCC sagging slab with dead load reduction.

consuming and costly

10 Crashed RCC balcony can be totally

Crashed RCC balcony repairs by RCC

replaced by ferrocement balcony

balcony is cumbersome costly and

with ferrocement chhajas, without

disturbance to occupants inside.

disturbance to occupants inside. This

Some times balcony provision is

balcony can have drop on sides with

cancelled.

dead load reduction. 11 Ferrocement Repairs and

Polymer treatment is without

rehabilitation treatment is highly

reinforcement. Guniting is reinforced

reinforced with small dia wire mesh

with weld wire mesh generally 10g

two layers at least with unreinforced and even 75x75mm single layer only, matrix size 6.00x6.00x1.5mm with

thickness 40mm or so. Polymer

low water cement ratio of around 0.4 treatment generate cracks along reinforcement in due course of time 12 Ferrocement finish surface is smooth/sand faced

Inevitable rough surface of guniting require sand face/smooth plaster. Thus extra expenditure.

Repairs/ (Replacement) of (Crashed) RCC Chajja, Balconies with Ferrocement Technology - RCC chhajas is of a building show sign of deterioration after 15-20years or some

times early. - Initially, there is cracking of plaster, peeling of cover of concrete and beginning of corrosion of steel reinforcements. - If condition as above is not attended, after certain few years spalling of concrete takes place on increased corrosion of reinforcement. The chhaja will loose its life. - On this development normally chhaja is dismantled, and reinforcement is cut off and chhaja provision is

cancelled.

A. Some times at this location another chhaja of (a) A.C. Sheet, (b) Aluminum, (c) G.I. Sheet, (d) FRP all with wood/ M.S. angel brackets and frame work is provided. Such chhaja has limited life. They are not waterproof at t and, cause deterioration of concrete and corrosion of reinforcement of adjacent beams/lintels of building. B. In this location it is possible to provide a ferrocement chhajas much superior to A.C. sheet, Aluminium, G.I. sheet and FRP. (i) Ferrocement chhajas is stronger than RCC and much stronger than Aluminum, G.I., FRP (ii) The thickness of ferrocement chhajas is 25-30mm. (iii) It is attached to the building by our anchoring system. (iv) The chhajas is totally waterproof and junction with building taken special cares to make waterproof. (v) No repeat waterproofing treatment is required. (vi) There is considerable dead load reduction. (vii) Ferrocement chhajas shall last several decades. - For some building where RCC balconies collapse due to corrosion and

deterioration of concrete, ferrocement balcony is the best solution. Simultaneously there will be dead load reduction and no disturbance and dismantling to inside of room. - It is best to provide ferrocement chhaja, lintels, balcony right at the time of building construction. Ferrocement cantilever balcony being less in weight by about 70%, damaging effect by earthquake is the least.

FERROCEMENT – Repair & Rehabilitation We carry out inspection study and suggest our own rehabilitation methods and systems, which are far superior to the conventional, as generally described below. Ferrocement protective anti-corrosive crack resistant membrane treatment is far superior to guniting because we use wire mesh layers with small dia wires, say 22 g at spacing of about 12 mm center to center and high quality vibrated cement matrix with reactive chemical coatings and finally finished smooth with the surface with the same finish as plaster. Another advantage of ferrocement is that this treatment can be carried out in patches such as junction of beams, columns, slabs, bottom of beams, middle portions of beams soffit of slabs, etc., In the case of guniting this is not possible from the practical point of view and perhaps if attempted, the cost will be prohibitive. The finished surface of guniting is rough and particularly in the areas within the building premises another coat of plaster has to be applied, whereas this is not the case in ferrocement. In such case the cost of the work shall come

down. In the case of epoxy and chemical rehabilitation treatment the surface are required to be highly dust-proof which is generally not possible in repairs and rehabilitation works. Therefore, adhesion may not be as strong as required. Secondly epoxy and chemical treated system cannot take large compression, shear and structural stresses. It is found after certain period the treated with such methods do develop cracks. The epoxy treatment loses strength in case of fire at very low temperature, i.e. about 50 degrees C. Therefore, in the long run the structure will start again deteriorating. These types of treatments are non-family material treatment and therefore at some stage or other are likely to be detached. Whereas ferrocement is the same family material as the RCC on which the rehabilitation is required to be carried out and ferrocement is far better in comparison as described further.

Ferrocement weather shed Vis-à-vis Aluminium/G.I. /A.C. sheet/FRP Weather shed Sr. Ferrocement Weather Shed of Aluminium/G.I./A.C. sheet/FRP No. weather shed of balcony Balcony 1 Junction of Ferrocement weather shed The Junction of Aluminium/G.I./A.C. with beams/ Lintels/pardi is perfectly sheet/FRP weather shed is finished

waterproof.

with cement mortar vata. This will crack after 4-5 years and required to be redone. In any case there will be leakages of water inside the flat.In due course concrete of lintels /beams /pardi will spall and reinforcement will corrode.

2 Ferrocement weather shed is

There is no anchoring system in case

connected to lintel, beams, pardi by

of Aluminium/G.I./A.C. sheet/FRP

anchoring and strape connection At

weather shed. The

the most cantilever anchor beams are weather shed is ed on wood/ provided in case 1.5 -2mtr

M.S. frame and brackets.

cantilevers. 3 It is very elegant- looks part of the structure.

It looks dissimilar- much below standard and shall look ugly in comparison.

4 In this weather shed no maintenance

Has to be repaired after 5-7 years.

is required. 5 Ferrocement weather shed is life time Has to be replaced after 10-12 years. provision. 6 Dust collection will be there but

Dust collection on FRP weather shed

acceptable. 7 There is no corrosion phenomenon.

looks very bad from below. Aluminium/G.I. sheet weather shed and M.S. brackets will corrode although painted.

8 Ferrocement weather shed is stronger Aluminium/G.I./A.C. sheet/FRP than Aluminium/G.I./A.C. sheet/FRP

weather shed is much weaker than

weather shed.

ferrocement.

9 Ferrocement weather shed is a guaranteed work

Aluminium/G.I./A.C. sheet/FRP weather shed is not a guaranteed work.

Ferrocement Repairs & Rehabilitation Chhajja Attachments

Crashed Balcony

Old deteriorated leaking weather shed over balcony replaced with new ferrocement waterproof weather shed with assured waterproofing at junction, for Co-OpHsg. Society at Vidyavihar.

Closed view of new Ferrocemen t Balcony Wit h roof drop pardi And weather Shed

Ferrmocement Chajja

Attachment to the

bungalows.

Over all view of new set Of ferrocement

Ferrocement Chajja attachment to the window showing load bearing

Balconies From Gr. To 4th floor

Old RCC chhajas 125mm thick replaced with new ferrocement

Repairs to thin deteriorated RCC fins. Repairs done with method of wrapping of wire mesh layers and high quality vibrated cement matrix.

Ferrocement Chajja Attachment to the windows of the bungalows.

Ferrocement Repairs & Rehabilitation

A ferrocement water tank could efficiently take onslaught of falling coconut tree with nominal damage in view of high- energy absorbing capacity. The repair cost was a fraction of cost of the tank, which would require total replacement of it was plastic or steel tank.

Ferrocement Chajjas to cover windows missed originally.

Ferrocement Chajjas to a multi-storey

Horizontal extension of a room upto 1.5 Mtrs.

Balconies and Chhajja Attachments

FERROCEMENT MEMBRANE WATERPROOFING

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

FERROCEMENT WATERPROOFING Waterproofing to R.C.C. structure is carried out with modern material known as Ferrocement. It is carried out generally in two layers of about 8 mm thickness each layer. It consists of iremesh reinforced cement matrix layers which are vibrated in situ. The top surface also vibrated finished smooth with nonmetallic fibres impregnation. The cement matrix and wiremesh layers are laid alternately. Each cement matrix layer is laid on a bond coat for assured integrity. Each wiremesh layer is fixed with u-clips to the base. The performance of the treatment is most excellent. Because in situ low water cement ratio cement matrix is vibrated and become dense with nil/negligible pores. The wiremesh layers generally two nos. prevent crack formation, if at all due to shrinkage, temperature or structural relative movements. Therefore the treatment is durable and permanent. It takes ware and tare efficiently due to certain ixtures. The wiremesh layers add strength to the main structure in addition to crack formation prevention. It is laid on insulated foundation layer of about average thickness of 40 mm. There will be dead load reduction to conventional brickbat coba treatment. It adds strength to base structure.

The waterproofing of the tank from inside saved the same from getting demolished. There are other instances of tanks where several types of water -proofings failed.

WATERPROOFING OF SUBWAYS AND BASEMENTS BY FERROCEMENT WATERPROOF S.

Waterproofing of subways and basements is best carried out using Ferrocement waterproof s boxing. Ferrocement waterproof s are manufactured on machinery set up under controlled conditions. The s are manufactured with least water cement ratio of around 0.35, well vibrated mechanically and sand cement ratio about 2.5. Wire mesh layers confine cement matrix and makes all the more resistant to crack formations if at all. The s are laid horizontally on plain cement concrete for raft and ed with high quality vibrated cement duly welded and wire mesh lapping. Therefore s are totally waterproof. On these s reinforcement of raft is laid and concreting carried out with total Waterproofing provision. For walls reinforcement is erected waterproof s are erected vertically on the outside. The wall s are connected with ferrocement s of raft. The s act as formwork. Concreting of walls is carried out with conventional formwork on the inside. Thus wood/steel shuttering is eliminated on the outside. To that extent, cost of formwork is reduced. The reinforcement of Ferrocement s for raft as well as walls can reduce the reinforcement of raft and walls to certain extent. The Ferrocement Formwork s add strength to raft and walls. Ferrocement precast boxing is most efficient and assured waterproof treatment leaving no chance for any leakages.

CORROSION RESISTANCE - Corrosion is a menace to the nation - It costs to the nation Rs240,000 crores

every year. For

For Centuries we have accepted Menace of Corrosion of steel

Centuries we have accepted Menace of Corrosion of steel - It is worst disaster economically except

negligible loss of human

Eliminate Corrosion of steel By Practicing Ferrocement Technology

life - Let us prevent corrosion by adopting Ferrocement Technology

For Centuries we are tired with Corrosion of Steel

Let‟s make Corrosion of

It will be no more with advent of

Steel a Matter of

Ferrocement Technology

Past

Corrosion of Reinforcement The corrosion of reinforcement in Ferrocement is most insignificant. The water cement ratio is the least giving least extra water to react with wiremesh reinforcement. There may be corrosion of brown colouring with wiremesh reinforcements which is not strong enough to burst cement matrix. In view of evenly spread wiremesh reinforcement, the corrosion is the most negligible and can be said to be not at all causing any damage. We can say the minute corrosion is dormant in the case of Ferrocement. This is the feature of Ferrocement unless it is manufactured with inferior materials and inferior workmanship in slipshod manner. In view of this and cement matrix being of superior quality, spalling / splitting will not take place.

We have been practicing Ferrocement Technology since more than 25 years by now. In our Ferrocement products, we maintain water cement ratio to be 0.35 to 0.4. We invariably vibrate our Ferrocement products either on machinery set up under controlled conditions or in- situ. In all our products to make it dense, we use ixtures to produce maximum strength and add many positive aspects to the materials. We use non- metallic fibers in the top of finished matrix. In view of such method of manufacture, we do not find any deterioration of our product and no problem so far as water proof quality of Ferrocement is concerned. In our Ferrocement products, there is no carbonation phenomena. We claim our method of manufacture is most meticulous with high quality and superior materials and workmanship. We are confident that our structures are bound to perform in a far superior manner.

Durability against Corrosion in Ferrocement

Ferrocement roofing s manufactured in the year 2000.

Most hard skin of the roof cast

Enlarged view of one Ferrocement roof for corrosion testing. Springling of water done and wet mapping lines visible.

Closer view wiremesh reinforcement

in the year 2000, could not be removed by chiseling. Had to be removed by Cutting wheel carefully not to damage the wiremesh. Most superficial line mapping on pouring of water on the surface disappearing within a minute or so.

showing no corrosion of wires but nominal brown colouration – indicating no possibility of corrosion for atleast further decade or so. ie the year 2020.

Corroded metal roofs, Detroit, USA

Such corrosion is not possible with Ferrocement FERROCEMNET ROOF The ferrocement roof consists s 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 s are ed monolithically. There will be no nuts and bolt arrangement as in the case of AC sheet Metal, FRP roofs. But ferrocement s 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, tless roof eliminating trusses and purlins nuts and bolts and ts 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. tless 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.

•

Ferrocement roof is trouble free and durable for decades.

Ferrocement ROOFING –I/II:

The structural steel frame work of portals and purlins in position being made ready for insitu ferrocement concrete work. Span 12.2 Meter

Ferrocement roof for the corrodo view from the inside.

View of the roof from inside The fans and lectrical

fittings attached to roof can been

seen.

View of the roof from top. Ready for matrix

The Structure size 6x3x2.1 M- Mtrs. height.The walls and roofs are cast in situ. Ferrocement plates about 25mm thick. Therefore carpet area is more as compared to brickwork

View of the roof from inside and ing system for a society Apartment.

This is a complete Kiosk structure with ferrocement foundation, walls, columns and roofs. Most appropriate for resorts structure and fast food kiosks.

View of the roof from outside

Ferrocement beam being lifted to 8th floor level

Ferrocement roof being lifted to 8th floor level

Ferrocement ROOFING –II/II:

This is a roof of a small structure with cast insitu treatment. The white band all around is also of ferrocement. The size of the roof is 6x3x1.2 Mtr. ht.

This is inside of the roof consisting of ferrocement portals and purlins. All cast insitu finish smooth. Electrical installation fixed to the roof is visible.

Ferrocement structurals trusses and purlins to roof s

Ferrocement roof interlocking tiles size 1.2x0.9mt. X20mm thick. Size can be increased to 2.4 x 1.2 mtrs. x 25mm thick or so and laid in position with new arrangement ed by ferrocement portal

Dome Dia.4.00 Apex 1.5 M. and thickness 25mm. smooth finish on top on sofit. No water proofing treatment necessary.

Corroded metal roof, Detroit, USA Such corrosion is not possible with Ferrocement.

Ferrocement ROOFING –III/III

Tarpaulin over leaking Roof. No such covering required over Ferrocement Roof for lifetime

The elegance of soffit of Ferrocement roof.

Tarpaulin over leaking Roof. No such covering required over Ferrocement Roof for lifetime

Canopy with Columns in front of building

Increase in storage space as compared to Steel trusses.