“Military Institute of Science & Technology (MIST)

Environmental, Water Resources and Coastal Engineering Department

”
EWC 201: Construction Materials
3 Credit Hours
FERROCEMENT
FERROCEMENT
• Ferrocement is a construction material consisting of wire meshes and
cement mortar.

• Applications of ferrocement in construction is vast due to the low self

weight, lack of skilled workers, no need of framework etc.

• Quality of ferrocement works are assured because the components are

manufactured on machinery set up and execution time at work site is
less.

• Cost of maintenance is low.

• This material has come into widespread use only in construction in the
last two decades.
PROPERTIES OF FERROCEMENT
• Highly versatile form of reinforced concrete.

• It’s a type of thin reinforced concrete construction, in which large amount of

small diameter wire meshes uniformly throughout the cross section.

• Mesh may be metal or suitable material.

• Instead of concrete, Portland cement mortar is used.

• Strength depends on two factors quality of sand/cement mortar mix and

quantity of reinforcing materials used.
Constituents Materials for FERROCEMENT
• Cement
• Fine Aggregate
• Water
• Admixture
• Mortar Mix
• Reinforcing mesh
• Skeletal Steel
• Coating

Fig: Typical cross section of ferrocement structure.

 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 (1.18 mm)

• Grading of sand should comply with the following table:

 Table: Guidelines for Grading of Sand

Sieve Size (%) Passing by weight

#8 80-100
#16 50-85
#30 25-60
#50 10-60
#100 2-10
 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
Advantages and Disadvantages of Ferrocement

Advantages:

• Basic raw materials are readily available in most countries.

• Fabricated into any desired shape.

• Low labour skill required.

• Ease of construction, low weight and long lifetime.

• Low construction material cost.

• Better resistance against earthquake.

Disadvantages:

• Structures made of it can be punctured by collision with pointed objects.

• Corrosion of the reinforcing materials due to the incomplete coverage of

metal by mortar.

• It is difficult to fasten to Ferrocement 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.
Process of Ferrocement Construction:

• Fabricating the skeletal framing system

• Applying rods and meshes
• Plastering
• Curing

Applications of Ferrocements in Construction:

• Housing
• Marine
• Agricultural
• Rural Energy
• Anticorrosive Membrane Treatment
• Miscellaneous
CORROSION
CORROSION : DEFINITION & TYPES
Corrosion is defined as an act or process of gradual wearing away of a
metal due to chemical or electro-chemical reaction by it’s surroundings
such that the metal is converted into an oxide, salt or some other
compound.

Two types of corrosion are,

• Dry Corrosion: chemical reaction between metal and gas or liquid in

the absence of electrolytes (substance that dissociates into ions in
solution or when fused and becomes electrically)

• Wet Corrosion: when the electrolyte causing corrosion is an aqueous

solution of acid, salt or alkali. Corrosion process involves an anodic
and cathodic reaction.
Dry Corrosion

• Dry corrosion occurs when there is no moisture or water to aid corrosion.

The metal in such a situation oxidizes with only the atmosphere. This process
is very sensitive to temperature, as can be demonstrated by holding a
piece of metal to a flame and observing the layer of oxide that forms.
• At ambient temperatures, most engineering metals are known to have slow
oxidation rates in a given atmosphere. The mechanisms involved make
different metals corrode at varying rates. When oxygen gas comes into
contact with a metal surface, this causes an oxide layer to form around the
metal. The layer of metal oxide limits the amount of oxygen able to reach
the metal surface, thus the rate of corrosion is reduced.
• Under hot conditions, dry corrosion occurs at a much faster rate as
compared to normal conditions. Alloys rely on the oxidation reaction where
they develop a protective scale that resists further corrosion attack. This
includes sulfidation and carburization among other attacks of high
temperature.
Wet corrosion

• Wet corrosion refers to the degradation and/or rust formation on a

metal surface that occurs due to the generation of a reactive
electrochemical cell. Wet corrosion can damage metal structures and
equipment, including stainless steel.
• Wet corrosion forms when two different metals are in contact with each
other while situated in a fluid environment with salt concentrations. This
environment creates an electric potential between the two metals, with
the more reactive metal undergoing oxidation and the loss of electrons.
Seawater, chloride solutions and acids are some typical electrolytic
environments in which wet corrosion occurs. It can be prevented by
eliminating the moisture.
DISADVANTAGES OF CORROSION:

• Weakens material due to prolonged corrosive action.

• loss, contamination, and deterioration of the appearance of a material.
• safety, health and environmental risks due to corrosion, especially in
manufacturing plants.
• Corrosion tends to vent in technical malfunctions in

ADVANTAGES OF CORROSION

• Corrosion of a material has to be renewed, thus giving scope of continuous

demand for materials.
• Corrosion becomes advantageous when a surface produces an oxide film
that will keep corrosion from proceeding further; which happens to
aluminum
Thank You