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
