Ferrocrete

Ferrocrete is derived from the words i.e. ferrous and concrete, ferrous means anything made from iron and concrete, which is made from cement, fine aggregate (i.s. sand), coarse aggregate (i.s. trap metal or broken pieces of stones), and water.

It is applied over an “armature” of metal mesh, woven, expanded metal, or metal-fibers, and closely spaced thin steel rods such as rebars.

Here we will learn about ferrocrete, properties of ferrocrete, advantages & disadvantages of ferrocrete.

Introduction to ferrocrete:

Ferrocrete is a form of reinforced concrete that is used with multiple layers of mesh and/or small diameter rods, which are completely infiltrated with or encapsulated in mortar.

The primary component of concrete is portland cement, ferrocrete has high initial strength portland cement.

Portland cement which is particularly suitable for:

• Facilitating the early de-molding, handling, and use of the precast concrete unit.
• Maintaining production in cold weather
• The early striking of formwork.

Properties of Ferrocrete:

• Ferrocrete is chemically similar to Procem i.e. Portland cement.
• It is more finely grounded than Procem, hence it give-higher early strength properties.
• Also, stiffens and sets at a similar rate to Procem.
• It does not comprise any added accelerators or admixtures.
•  Its color is like Procem from the same works and different properties are much like Procem.

Advantages of Ferrocrete:

1. It is less weighty than fiber-reinforced plastic (fiberglass), aluminum, or steel frameworks.
2. It has lower strength and lower durability than standard RCC construction.
3. Also, they are mechanically overloaded, it will bend rather than crack or break.
4. It is 10 to 25% of the weight of a comparable construction made of bricks.
5. The sleek sections make it more aesthetically attractive.
6. It can be made in any size, so a biological shape is possible.

Disadvantages of Ferrocrete:

1. Construction is labor-intensive.
2. Skilled labour is required.
3. Structures are less strong.

 Applications of Ferrocrete:

• It produces high early strength in a wide variety of concretes, mortars, and grouts.
• It facilitates the early de-molding, handling, and use of all kinds of precast concrete products.
• Also, reduces formwork putting instances.
• It helps to take care of normal concrete manufacturing throughout the cold climate.

Uses of Ferro-crete Technology:

1. Ferrocrete purlins are designed as a logical alternative to factory-built systems.
2. The construction of the ferrocrete channel with simple modifications made into extra viable, environment friendly, and applicable building materials used along with MCR tiles.
3. Ferrocrete building likes floors, ceilings, and walls for residential places and workplace buildings.
4. Ferrocement ducts are appropriate for the circulation of cool or hot air and they are structurally sturdy.
5. In addition, they are able to resign atmosphere damages and they are superior to many of the conventional ones.
6. Ferrocement plated RCC structure is a heterogeneous material with voids and capillaries.
7. These are crammed with water causing spalling of concrete crack formations.
8. Water storage tanks are constructed using ferrocement plates of 25 mm to 30 mm thick, it is strong like metal plates and is completely waterproof.
9. The footbridge that is used to cross a road, rail track, these bridges are fabricated with supporting columns, stairs, roof and so on, as per requirement
10. Manhole covers are superior in high quality and sturdiness as compared to the standard ones.
11. Heavy-duty, as well as the lightweight cover, makes them excellent for busy locations.

Also read: Papercrete, Geosynthetics & Concrete Joint filler

Conclusion:

Ferrocrete is a form of reinforced concrete, using several layers of mesh or small diameter rods, which are fully penetrated or enclosed in mortar.

It has the ability to stand for thousands of years, once set in high density.