Ferrocrete - Construction, Design and Application · Ferrocement or Ferrocrete, is a relatively...
Transcript of Ferrocrete - Construction, Design and Application · Ferrocement or Ferrocrete, is a relatively...
One Day Workshop on
Ferrocrete - Construction, Design and Application
Wednesday, 2nd January, 2013; 9:30 am to 6:00 pm
Department of Civil Engineering
Vishwakarma Institute of Information Technology
Kondhwa (Bk.), Pune 411048
Ferrocement or Ferrocrete, is a relatively thin structural composite material, made by
sandwiching one or two layers of either welded steel wire mesh/expanded mesh/ chicken mesh in
cement mortar. The cement mortar consistency is such that it is generally hand-pressed and
finished manually with semi-skilled applicator. Unlike R.C.C., Ferrocrete has a continuous and
well distributed grid of mesh reinforcement, resulting in better crack resistance, higher tensile
strength to weight ratio, ductility and impact resistance than conventional reinforced concrete.
(For more details refer to the web link: http://www.ferrocementindia.com/)
Large numbers of Ferrocement works are going on in India. As such the civil engineering faculty
and students must have the update knowledge of the Ferrocement technology. They must always
know where such technology is already applied and could be applied in construction.
Vishwakarma Institute of Information Technology is organizing a one day workshop on
“Ferrocrete- Construction, Design and Applications” in association with the Ferrocement
Society, Pune to provide information about the latest developments in ferrocrete design and
applications
Workshop Objectives:
1. Learning the engineering fundamentals of Ferrocrete
2. Introduction to the construction materials and techniques used in the fabrication of Ferrocrete
3. Discuss the economics, research and quality control issues associated with Ferrocrete
The one day workshop was organized in association with the Ferrocement Society at the
Department of Civil Engineering, VIIT, Kondhwa, Pune, Maharashtra, on 2nd
January, 2013. The
workshop was part of a Faculty Development Programme for the department. 20 professionals
from the industry and academia and about 130 Civil engineering students attended the workshop.
List of Key Speakers (Photo-1) from Ferrocement Society for the workshop were as follows;
1) Dr. B. N. Divekar – Director, Ferrocreator, Pune
2) Prof. R. K. Ambegaonkar – Former Chairman of B.O.S. Metallurgy & Dean , Faculty
of Engineering, University of Pune
3) Arch. Jayant Patankar – A consulting architect, Mumbai
4) Er. N. S. Jadhav – Contractor, Pune
5) Er. Pushyamitra Divekar – Contractor, M/S Prefercon, Pune
Photo-1: Ferrocrete Worshop – Keynote Speakers
The workshop started on time at 10:15 am with a warm welcome from Prof. S. P. Nitsure, HoD-
Civil Dept., and VIIT. Printed technical handouts were distributed to all the attendees. Dr.
Divekar’s recently published book titled “Ferrocrete Technology” was also displayed and
introduced to the audience. A short introductory film about Ferrocrete was shown.
Thereafter, Dr. B. N. Divekar (Consultant/Researcher & Ferrocrete-Guru) who has more than 30
years’ experience in Ferrocement design and constructions explained the basic philosophy of
Ferrocrete - Material and Structural System. He also clarified the construction details and
procedure of Ferrocrete technology. New research ideas in structural applications of Ferrocrete
i.e. Meshcrete, was also discussed. Dr. Divekar discussed the newly developed concept of ‘All-
in-One’ ferrocrete construction. Many new concepts like cavity walls, hollow floors, in-built
framework, arch faced retaining walls, petal tanks, stiffened plates were introduced by him along
with lots of illustrative construction projects and photographs.
The conducted programme details are given in Table-1.
Table-1: Programme Details
Time Activity Details
09:30-10:00 Registration of delegates E-214, Bldg-E, VIIT, Pune
10:00-10:15 Tea Break E-214, Bldg-E
10:15-10:30 Welcome and Inaugural function Prof. S. P. Nitsure, HOD
10:30-10:45 Introduction to Ferrocement
- a short film Ferrocement Society
10:45-12:00 What is Ferrocement?
Basics and design of structures
Dr. B. N. Divekar,
Director, Ferrocreator, Pune
12:00-12:30 Ferrocement - Materials & QAQC Prof. R. K. Ambegaonkar
12:30-1:30 Demonstration of Construction
- of Ferrocrete Panel at VIIT Dr. B. N. Divekar and Team
1:30-2:15 Light Lunch - Break
Room D-002, Civil Dept.
2:15-3:00 Ferrocement in building
Construction – Architects Views
Arch. Jayant Patankar,
Construction expert
3:00-3:45 Ferrocrete Applications Er. N. S. Jadhav, Ferrocrete
Contractor
3:45-4:00 Tea break Room E-214, Bldg-E
4:00-5:00 Applications of Ferrocrete – Case
Studies and Experiences Er. Pushyamitra Divekar
5:00-6:00 Discussions/Concluding session Ferrocement Society - Team
Dr. Divekar showed how appropriate geometry and shapes can give strength to any structure
using some simple wooden and thermo-col models (Photo-2). Ferrocement bends but does not
crumble in to discrete separations like R.C.C and hence has enhanced energy absorption and
ductility required for construction of Earthquake resistant/safe structures.
Dr. B. N. Divekar then explained about his patented thermo coal sandwiched panel walls – which
are popularly used in the mass housing and compound wall construction. He advised the students
to have this as a research project work. Dr. Divekar also advised the attendees to start a
proprietary business/consultancy in Ferrocrete design and construction instead of working for
other companies after graduation.
(a)
(b)
Photo-2: Ferrocrete Worshop – Keynote Presentation by Dr. Divekar
Prof. R. K. Ambegaonkar then explained the function of each of the ingredients in Ferrocrete
including their engineering and material specifications. He informed that OPC Cement with or
without fly-ash, fine aggregates and water in proportions of 1:2 or 1:3 with water-cement ratio of
0.40 is generally used to make the mortar. Details about the various types of steel reinforcement
such as - welded wire mesh, expanded mesh and chicken mesh were provided through his talk.
He deliberated about the eco-friendly nature of Ferrocrete and enlightened the audience about
future materials that could be used in Ferrocrete. All the attendees showed keen interest in the
interactive discussions at the workshop (Photo-3).
(a)
(b)
Photo-3: Ferrocrete Worshop at VIIT, Pune – 150 Attendees
The end of 1st Secession of workshop was marked by a much awaited demonstration of an actual
Ferrocrete panel construction at VIIT Laboratory. All the participants took great interest in this
activity. Students under the guidance of Dr. Divekar and team, mixed appropriate proportions of
cement, sand and water to produce mortar (Photo-4).
Students Mixing Cement Mortar for the Demonstration
Casting of a Ferrocrete Panel by the Students
Press-Filling a Ferrocrete Panel by Students at VIIT, Pune
Photo-4: Live Demonstration at Ferrocrete Worshop
“Khada-Thapi” (upright-trowel) test to verify the appropriate consistency of the ferrocrete
cement mortar was also demonstrated by Dr. Divekar. Then the panel was press-filled with
cement mortar using two trowels from either sides of the ferro-grilled mesh, by the students.
Attendees had a spontaneous and interactive discussion with the experts at the demonstration
(Photo-5).
Photo-5: Students Discussing with the Experts During Demonstration
Post lunch session was initiated by architect Mr. Jayant Patankar. With the help of 3-D
architectural modeling presentation, he explained how effectively ferrocrete systems and
elements can be used for simple yet beautiful aesthetes. Mr. Patenkar showed several
photographs of many projects that demonstrated the versatility and simplicity of Ferrocrete
systems.
Later, Er. N. S. Jadhav, a ferrocement professional/contractor shared his inspirations and
experiences related to Ferrocrete. He has undertaken a unique house building at Satara, which he
discussed in details and showed numerous photographs for better understanding. Use of
ferrocement for all the components is the specialty of this building. Mr. Jadhav has constructed
floating ribbed/cellular platforms on water, industrial shades, fins, caves and planters, domes and
cornices, watchman cabins, interiors and many allied constructions using structural or non-
structural forms of Ferrocrete (For more details refer - http://www.deepferrocement.com/). This was a very
interesting talk by Mr. Jadhav which opened up a new thought process in the minds of the
attendees.
Er. Pushyamitra Divekar, a Ferrocement professional in Pune, discussed various projects which
he has constructed using ferrocement technology during the last decade. He informed that
ferrocement walls can save 40 to 60 percent cost against the traditional RCC retaining walls.
Cases of Ferrocrete bungalow entrance gate, swimming pools, pergolas, doors, walls, lintels,
stairs, water tanks, and decorative elements were discussed. Er. Divekar highlighted the main
advantage of Ferrocrete in construction industry, i.e. saving of construction time, material and
money; thus making it a green material.
At the end of the workshop, a question and answer session was organized in which a lot of
technical questions on ferrocement and its applications were asked by the participants and all the
questions were duly answered by the speakers.