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Ferrocement Technology GOVERNMENT OF MAHARASHTRA WRD HANDBOOK CHAPTER NO. 1 FERROCEMENT TECHNOLOGY MAHARASHTRA ENGINEERING RESEARCH INSTITUTE, NASHIK-04 WATER RESOURCE DEPARTMENT GOVERNMENT OF MAHARASHTRA WATER RESOURCES DEPARTMENT WRD Handbook Chapter No. 1 FERROCEMENT TECHNOLOGY Maharashtra Engineering Research Institute, Nashik 422004, India First Edition 2018 PREFACE Ferrocement technology was used in 1848 to build boats. The durability and imperviousness of this material is useful in buildings and some water retaining structures. BIS has already published IS code No. 13356:1992 (Precast ferrocement water tanks up to10000 litres capacity). Maharashtra Engineering Research Institute has been doing research and testing of the components since 1979. This technology can be used in building components, irrigation structures and canals, rehabilitation and strengthening of old structures etc. As there is no literature or consolidated compiled information available for the guidance of field engineers, hence this manual was a need of the civil engineers working in this field. Government of Maharashtra, WRD instructed to prepare manual for field engineers. As per Maharashtra Government resolution, Water Resource Department MSS 1114/(case no. 365 / 2014) MP-4 date:03/01/2015, Government formed a committee to prepare a WRD Handbook on ferrocement. This committee conducted six meetings and prepared the draft copy of this handbook. Accordingly the report containing draft manual was submitted to Government of Maharashtra and Government of Maharashtra accorded sanction vide letter dated 14/06/2018 This handbook will serve as a reference book to field engineers. This WRD handbook chapter no. 1 mainly contains description for following topics. 1. Materials 2. Equipment and Tools 3. Testing of materials (Field tests) 4. Laboratory Tests 5. Applications of ferrocement 6. Methods of construction 7. Design of ferrocement structures 8. Cost estimation of ferrocement structures 9. Standardization of ferrocement 10. Research work 11. Ferrocement use on experimental basis This manual is prepared with great technical contribution from Dr Balkrishna Divekar, retired professor of engineering college and past chairman of Ferrocement Society of India, Pune and all the committee members as mentioned in Appendix 1. I take this opportunity to thank all committee members for their contribution. I am sure that this book will be useful for engineers from all departments of Government of Maharashtra to have basic introduction of ferrocement technology. Since WRD has published its separate Manuals, CSR etc., the series of such Handbook Chapters is first one published by WRD. I am happy to publish this chapter of first WRD manual. Hope, it shall be useful for the engineers for the successful implementation of the Ferrocement Technology in various departments of Government of Maharashtra considering its unique features such as imperviousness (crack free surface), slim components, mouldable to any shape (without formwork), sustainable to seismicity, eco-friendly, ease of construction, precasting, more strength to weight ratio and so many features. (Rajendra Pawar) Director General Design Training Hydrology Research and Safety Maharashtra Engineering Research Institute, Nashik I LIST OF PWD HANDBOOK CHAPTERS 1. Materials. 2. Masonry. 3. Reinforced Concrete Construction. 4. Prestressed Concrete. 5. Plastering and Pointing. 6. Preparation of Projects and Engineering Geology. 7. Surveying. 8. Excavation. 9. Foundations. 10. Building. 11. Town Planning. 12. Roads. 13. C.D.Works and Bridges. 14. Ports and Harbours. 15. Runways and Air-strips. 16. Electrical Works Connected with Buildings. 17. Soil Mechanics. 18. Hydraulics. 19. Hydrology and Water Planning. 20. Masonry and Concrete Dams, 21. Earth and Composite Dams. 22. Instrumentation. 23. Spillways, Outlets, Gates and Hoists. 24. Canals. 25. Irrigation and Irrigation Management 26. Soil Survey of Irrigation Command, Land Drainage and Reclamation. 27. Hydro-power Scheme. 28. Construction of Tunnels. 29. Urban Water Supply. 30. Rural Water Supply. 31. Sanitary Engineering. 32. Construction Machinery. 33. Quality Control: Part I : Cement Concrete, Part II : Earth Work 34. Labour Laws. 35. Rate Analysis. 36. Construction Planning. 37. Part-I -Land Acquisition Part-II- Valuation. 38. Mathematical Data and Miscellaneous Information. 39. Colgrout Masonry works. 40. Placement of concrete 41. Ready Mix Concrete LIST OF WRD HANDBOOK CHAPTERS WRD1. Ferrocement Technology II Abbreviations ASTM-American Society for Testing Materials BIS- Bureau of Indian Standards ACI- American Concrete Institute NBC- National Building Code Lcr- Spacing of cracks. Cr –Crack width L –Bond length Sr- Specific Surface- Parameter defined as ratio of area of contact of wires to the volume of mortar which is bound by them. Vr- Volume fraction of steel Vs-Volume of steel wires in cc per sqm of area. Vm- Volume of mortar in length Lcr. III INDEX Page Sr.No. Chapter no. 1 Introduction 1 2 Terminology 5 3 Materials 7 4 Equipment and Tools 17 5 Testing of materials (Field tests) 20 6 Laboratory Tests 25 7 Applications of ferrocement 28 8 Methods of construction 45 9 Design of ferrocement structures 51 10 Cost estimation of ferrocement structures 67 11 Standardization of ferrocement 79 12 Research work 84 13 Ferrocement use on experimental basis 95 References 96 APPENDIX 1- List of ferrocement committee members 97 APPENDIX 2- Cost estimates of ferrocement items 99 APPENDIX 3- Use of Ferrocement in Earthquake Resisting 120 Structures APPENDIX 4- Structural analysis and design of siphon 131 using ANSYS APPENDIX 5- Photo section : Various ferrocement works 140 constructed across India APPENDIX 6- Formulation of Panel for ferrocement 146 APPENDIX 7- List of Figures 149 APPENDIX 8- List of Tables 152 IV CHAPTER 1 INTRODUCTION 1. 1 Introduction: Ferrocement is the composite of Ferro (Iron) and cement (cement mortar). Ferrocement can be considered as a type of thin walled reinforced concrete construction in which small-diameter wire meshes are used uniformly throughout the cross section instead of discretely placed reinforcing bars and in which Portland cement mortar is used instead of concrete. In ferrocement, wire-meshes are filled in with cement mortar. It is a composite, formed with closely knit wire mesh; tightly wound round skeletal steel and impregnated with rich cement mortar as shown in fig 1.1. Fig 1.1 Construction of ferrocement structure With Ferrocement it is possible to fabricate a variety of structural elements, may be used in foundations, walls, floors, roofs, shells etc. They are thin walled, lightweight, durable and have high degree of impermeability. It combines the properties of thin sections and high strength of steel. In addition it needs no formwork or shuttering for casting. Ferrocement have applications in all fields of civil construction, including water and soil retaining structures, building components, space structures of large size, bridges, domes, dams, boats, conduits, bunkers, silos, treatment plants for water and sewage. 1. 2 Definition of ferrocement Ferrocement is defined in different ways by different organizations. 1) According to United Nations High Commissioner for refugees (UNHCR), ferrocement is defined as ‘A thin walled construction, consisting of rich cement mortar with uniformly distributed and closely spaced layers of continuous and relatively small diameter mesh (metallic or other suitable material).’ (reference- UNHCR-Large ferrocement Water tank Manual July 2006). 1 2) ACI committee-549 describes it- ‘Ferrocement is a form of reinforced concrete using closely spaced multiple layers of mesh and/or small diameter rods completely infiltrated with, or encapsulated, in mortar. The most common reinforcement is steel mesh’ (reference – ACI 549.1R-93- Guide for the design, construction and repair of ferrocement) 1. 3 Historical background. Ferrocement has a history of more than 170 years. The idea of impregnating closely spaced wire meshes with rich cement mortar is similar to the Kood (कू ड) type of age-old method of walling. In Kood system, bamboo and reeds are tied closely together and filled in with a mix of mud and cow dung as a matrix. It is used in rural areas of India. Hence Ferrocement may be called as a modified form of Kood with standardized raw materials, systematic method of construction and reliable structural properties. Here the mesh is used in place of bamboo and reeds, and cement mortar instead of mud. Ferrocement in the form of mesh-reinforced cement mortar was used in Europe by Mr. J. L. Lambot in France. He constructed a ferrocement rowing boat in 1848, in which reinforcement was in the form of flexible woven wire mat and small size bars. He had patented this process. In the early 1940, Nervi of Italy used ferrocement for shipbuilding to overcome the shortage of steel plates in the world war-II. He also applied ferrocement techniques in buildings and warehouses. Ferrocement has been used in construction of domes, roofs of stadiums, opera houses and restaurants in Europe. In spite of Nervi’s demonstration of successful use of the material, no systematic studies were made till 1960, when its use as a boat building material was made in Australia, U.K., and South East Asian countries. In 1972, National Academy of Science, U.S.A., established an Ad-hoc panel to study the use of ferrocement in developing countries. Its report on ‘Ferrocement- Applications in Developing Countries’, was published in 1973. It gave impetus to
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