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CE 2101: Engineering Materials: Rumana Afrin

Ferrocement is a thin reinforced concrete made of closely spaced layers of wire mesh embedded in mortar. It has a higher ratio of steel to cement than conventional concrete. Ferrocement exhibits superior properties to steel or cement alone due to this combination. It is a durable and versatile building material that is lightweight, flexible, waterproof, and resistant to impact and cracking. Ferrocement can be manufactured through various techniques like hand plastering or mechanized processes and has applications in repairing slabs, walls, and construction of a variety of structures.

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58 views

CE 2101: Engineering Materials: Rumana Afrin

Ferrocement is a thin reinforced concrete made of closely spaced layers of wire mesh embedded in mortar. It has a higher ratio of steel to cement than conventional concrete. Ferrocement exhibits superior properties to steel or cement alone due to this combination. It is a durable and versatile building material that is lightweight, flexible, waterproof, and resistant to impact and cracking. Ferrocement can be manufactured through various techniques like hand plastering or mechanized processes and has applications in repairing slabs, walls, and construction of a variety of structures.

Uploaded by

Rumana Afrin
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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CE 2101: Engineering Materials

PART –B [1.5 Credits]

Lecture 3

Rumana Afrin
Assistant Professor,
Department of Civil Engineering, United International University
FERROCEMENT
Ferro cement is a form of thin wall reinforced concrete using closely spaced
layers of continuous and relatively small size wire mesh and/or small diameter
rods completely infiltrated with, or encapsulated in, mortar.

• Ferro cement is a super reinforced concrete.

• It differs from conventional concrete in that there is a higher ratio of steel to


cement mortar.

• Exabits properties, superior to either steel or cement separately.


Typical Section of Ferrocement

• Wire mesh
• Mortar

• 6 ~ 20 mm
Component Materials:
1. Mortar
• Cement
• Aggregate (sand)
• Water
2. Reinforcement
• Skeleton steel
• Steel mesh reinforcement

3.Chemical Admixture

The matrix constitutes 95% cement mortar & 5% wire mesh of the
composite.

Mortar provides the mass and wire mesh impart tensile strength and
ductility
Mortar

• Ordinary Portland cement and fine aggregate matrix is used.


• Sand, occupies 60 to 75% of the volume of the mortar.
• Plasticizers and other admixtures are used.

Mixed proportion:

• Sand: Cement (ratio by mass)


1:1.5 to 2.5
• Water: Cement (ratio by mass) 0.35 to 0.6
Reinforcement

Skeleton steel
•

•
STEEL
It support the steel wire mesh
Use to impart structural strength
3 to 8 mm steel rods are used
• Thickness varies from 6 to 20 mm according to loading condition.
• Generally mild steel is used.
• Spacing 7.5 cm to 12 m.
Steel Mesh Reinforcement

• Consists of galvanized steel wires of diameter 0.5 to 1.5mm, spaced at 6 to


20mm center to center.
• Welded wire mesh has hexagonal or rectangular openings.
Chemical Admixture in Ferro Cement

• Water reduction, with strength and reduces permeability.


• Air entrainment, which increases resistance to freezing and thawing.
• Suppression of reaction between galvanized reinforcement and cement.
Specifications of Materials as Per
Bangladesh National Building Code, BNBC

Cement:

• shall comply with ASTM C150-85a , ASTM c595-85 or equivalent


• shall be fresh
• Shall be of uniform consistency
• shall be free from lumps and foreign matter
• shall be stored under dry conditions for as short duration as
possible

Aggregate (sand):

• shall comply with ASTM C33-86 requirements (for fine aggregate)


or equivalent
• shall be clean
• shall be inert
• shall be free from organic matter and detrimental substances
• shall be relatively free of silt and clay (particles passing #200 sieve)
• Max particles size should be less than #16 (1.18mm)
• Grading of sand should comply with the following Table
Table: Guidelines for Grading of Sand

Sieve Size (%) Passing by Weight

#8 (2.36) 80-100
#16 (1.18) 50-85
#30 (0.60) 25-60
#50 (0.30) 10-30
#100 (0.15) 2-10
Table: Guidelines for Grading of Sand

Water:

• shall be fresh, clean and potable


• shall be relatively free from organic matter, silt, oil, sugar, chloride
and acidic material.
• Salt water is not acceptable
• shall have a pH>= 7 (non-acidic)

Reinforcement:

• shall be clean and free from deleterious materials such as dust,


loose rust, coating of paint, oil or similar substance
Properties of Ferrocement

• It is a very durable, cheap and versatile material.


• Better impact and punching shear resistance.
• Low w/c ratio produces an impermeable structures.
• Less shrinkage, and low weight.
• High tensile strength and stiffness.
• Undergo large deformations before cracking or high deflection.
Techniques of manufacturing
• Hand plastering
• Semi-mechanised process
• Centrifuging and guniting

Process of Construction by Hand plastering

• Preparation of mortar
• Fabricating the skeletal framing system with mesh
• The mortar is applied to the reinforcing wire with a trowel
• Curing
Advantages of Ferro-Cement

• 20% savings on materials and cost.


• Suitability for pre-casting.
• Flexibility in cutting, drilling and jointing.
• Very appropriate for developing countries, labor intensive.
• Good impermeability.
• Fabricated into any desired shape.
• Ease of construction, low weight and long lifetime.
• Better resistance against earthquake.
• Structures are highly waterproof and higher strength to weight
ration than R.C.C
Disadvantages of Ferro Cement
• Corrosion of the reinforcing materials due to the incomplete coverage of metal
by mortar.
• It is difficult to fasten to Ferro cement with bolts, screws, welding and nail etc.
• Large no of labors required.
• Cost of semi-skilled and unskilled labors is high.
• Tying rods and mesh together is especially tedious and time consuming.
• Low ductility.
• Susceptibility to stress rupture failure.
• It can be punctured by collision with pointed objects.
Applications of Ferro Cement
REPAIR OF SLABS WITH SPALLING USING FERROCEMENT
REPAIR OF WALLS WITH DAMPNESS
WHAT DOES FERROCEMENT REPAIR DO?

• Such repair with ferrocement increases the tensile stress capacity of concrete.

• Therefore, no further micro cracks can occur in concrete under normal


loading on the slab.

• As this reduces the possibility of further ingress of air through micropores of


concrete, the chances of spalling of concrete becomes remote.
Thank You

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