Use of ferro cement in construction

In the world of construction, ferro cement is emerging as an increasingly popular alternative to traditional reinforced concrete. Ferro cement refers to the application of cement over a metal mesh or metal fibres. As opposed to traditional concrete that uses steel rebar, ferro cement provides a lightweight alternative. In this article, we explore more about ferro cement, its features, applications and pros and cons.

See also: What is RCC in construction?

 

Features of ferro cement

Ferro cement is preferred due to its various superior features. Read on to find out more about these features:

Strength and durability 

High-strength and durability are the USPs of ferro cement structures. The combination of cement and a mesh of metal reinforcement makes it suitable for long-lasting applications. 

Lightweight 

Despite its strength, ferro cement is quite lightweight when compared to traditional concrete structures. This makes it easier to handle during construction and transportation. 

Versatility 

Being a super versatile material, ferro cement can be easily moulded into various shapes and sizes to suit a wide range of construction applications. Boat building, water tanks and housing are some common applications of this property.

Thin cross-sections

Ferro cement structures can be designed with thin cross-sections without compromising strength. This promotes more efficient use of materials and reduced construction costs.

Resistance to cracking

Due to its mesh reinforcement, ferro cement is resistant to cracking. It enhances the material’s ability to withstand tension forces and control and limit cracking.

Corrosion resistance

The metal mesh used in ferro cement is designed using corrosion resistant materials, such as galvanised steel. This significantly reduces the risk of rust and corrosion. 

Waterproofing

Ferro cement structures can be highly resistant to water penetration when properly constructed. This makes it suitable for applications like water tanks and boats.

Cost-effective 

In regions where traditional construction materials are expensive or difficult to obtain, ferro cement construction can prove to be a cost-effective alternative. 

Ease of repair

If damaged, ferro cement structures can be repaired without much hassle. Small cracks or damages can be easily patched up with appropriate materials.

Thermal insulation 

Ferro cement structures possess exceptional thermal insulation properties, helping to regulate internal temperatures in particular applications.

 

Applications of ferro cement

Being a versatile material, ferro cement is used in a wide range of applications. Following are a few of them:

Boat building

Ferro cement is a commonly found material in the construction of boats and small watercraft. It is water resistant and lightweight without compromising strength, making it an ideal choice for boat hulls.

Water tanks

The ability of ferro cement to resist water penetration makes it an important material in the construction of water storage tanks. It provides a durable structure that makes it suitable for water holding and storage purposes.

Housing and buildings

Ferro cement can be used for building walls and roofs, making it an important component of construction. Being a versatile material, it allows for the creation of unique and customised architectural designs.

Pipes and culverts

Due to its water resistant properties, pipes made of ferro cement are used in water distribution systems, drainage and culverts. The material’s superior corrosion resistance properties make it highly suitable for these applications.

Bridge components

Several components of bridges, like panels and decks, are constructed using ferro cement. This material offers optimal strength-to-weight ratio and durability, making it a viable option for these structural elements.

Fencing and boundary walls

Structures made from ferro cement are durable and have the ability to provide security while maintaining an aesthetically pleasing appearance. Therefore, it is employed in the construction of fences and boundary walls.

Sewage treatment tanks

Another utility of ferro cement’s water resistant properties is in its application in the construction of sewage treatment and septic tanks. It can resist water penetration and is durable, therefore being ideal for containing and treating wastewater.

Sculptures and art installations

The versatility of ferro cement is also useful for artists and sculptors as it allows them to create durable art installations. It can take on various shapes and sizes, making it a preferred choice of material for creative projects.

Decorative elements

When it comes to decorative elements, ferro cement is a useful material for landscaping, gardens and outdoor spaces. It is ideal for crafting of decorative features such as fountains, planters and outdoor furniture.

Military applications

Ferro cement also finds use in military applications such as construction of bunkers and protective barriers. It is a preferred choice of material for such applications due to its ability to withstand impact and provide structural strength.

 

Pros and cons

Now that you know of the applications of ferro cement, let’s find out if it is suitable for your needs. Here is a list of its pros and cons:

Pros	Cons
Structures made from it are known for their high strength, durability and relatively longer lifespan.	Usage can be labour-intensive, requiring high skills and attention to detail.
It is lighter than traditional concrete in spite of its durability, making it easier to handle and work with.	Achieving consistent quality is difficult and requires constant and rigorous control measures.
It can be moulded into various shapes and forms, ensuring versatility in design.	Despite the mesh reinforcement, it can crack if not properly designed or constructed.
Structures have thin cross-sections without compromising strength, ensuring efficient material usage and reduces construction costs.	It has limited load-bearing capacity compared to traditional reinforced concrete.
The metal mesh is corrosion-resistant and does not rust or deteriorate easily.	Structures are more prone to impact damage than other construction materials in case of marine applications.
Well-constructed structures show superior resistance to water penetration, making them ideal for water storage and marine applications.	Not suitable for heavy construction projects such as high-rise buildings or large infrastructure projects.
Small cracks and damages can be easily repaired.	Construction requires specialised knowledge of techniques or it might lead to performance issues.
Offers a cost-effective alternative in cases when traditional materials are not available.	The production of cement can contribute to environmental issues such as carbon emissions.
Structures have good thermal insulation properties, ensuring optimal energy efficiency.	It has a limited structural span and might need additional structural elements for support, like steel, in some cases.

 

FAQs

How is ferro cement different from traditional concrete?

Unlike traditional concrete that uses steel reinforcement bars, ferro cement makes use of a metal mesh to result in a lightweight but durable composite material.

What are the common applications of ferro cement?

Ferro cement is widely used in boat building, water tanks, housing construction, bridges, pipes, fencing and decorative elements.

Is ferro cement a cost-effective construction material?

In regions where traditional construction materials are difficult to obtain, ferro cement provides a cost-effective alternative. It is also easy to transport and use due to its lightweightedness.

What are the potential challenges in working with ferro cement?

Ferro cement construction can be labour-intensive and achieving consistent quality might be a challenge. The limited structural span is also a challenge.

How does ferro cement perform in marine environments?

Ferro cement is highly resistant to water penetration and corrosion and can withstand the harsh conditions of saltwater environments, making it a preferred material for marine vessels.

Can ferro cement be used for large-scale construction projects?

Since it has a limited load-bearing capacity and needs additional support in long spans, ferro cement is not the ideal choice for large-scale construction projects.

How does ferro cement contribute to environmental sustainability?

Ferro cement’s lightweight nature can reduce transportation-related carbon emissions. However, the environmental impact of cement emission is a key consideration.

Got any questions or point of view on our article? We would love to hear from you. Write to our Editor-in-Chief Jhumur Ghosh at jhumur.ghosh1@housing.com