Ferro Cement Construction

Ferro Cement Construction for Thin-Shelled Monolithic Shell Structures

Ferrocement or ferro-cement also called thin-shell concrete structures and ferro-concrete is a system of reinforced concrete using sand, cement and water applied over layers of metal such as bird mesh or chicken wire or woven or expanded metal (iron) mesh or fibers fixed to a frame of larger diameter reo bars. It is used to form relatively thin, hard, strong forms in many shapes for such applications as hulls for boats, shell roofs, dome-shaped structures, water features, garden planters and water tanks and a whole range of magnificent ferro cement structures.

The artistic curvature of Javier Senosiain’s bioarchitecture illustrates a type of design freedom that only ferro cement can provide. His design is known as “Tiburón” (shark).

tiburon ferro cement structure

Steel can be replaced with fibreglass or basalt fibre, mesh and REO bars and even bamboo. Yes, bamboo has been used as reinforcement in concrete for hundreds of years and is still in use today.  In fact, there is a revival of using bamboo to fabricate extremely strong and creative designs to which mesh can be attached for rendering into a monolithic shell structure.

Ferrocement structures have several advantages over those constructed of timber or regular reinforced concrete, strength and flexibility are most notable. Great strength contributes to the following three:

  • Lower maintenance, to almost zero
  • Reduced need for structural insurance,
  • Longevity
  • Withstands extreme weather
  • Earthquake resistant

All the above advantages are totally dependent upon employing good methods and materials. The design of ferro cement structures increases design freedom gained by the easy use of curvature as well as straight lines.

 

Bamboo Mesh and Render

Working with bamboo, meshes and fibers is a very effective way of fabricating the shape in a reinforcing matrix that forms a support system that is utilized only once, as a frame for the structure. The bamboo frame is supported during construction which is in turn encased in cement and becomes the supporting mold for the construction of the ferro cement shell structure by building layers of renders to achieve the desired thickness.

Bamboo/ferro cement dome shell structure workshop by Chris Brown of Domeshells.com.au Bamboo mesh and render dome

Another Example by Shannon McCabe in Bali using the 3 Jet Combo Render Sprayer

Bamboo Ferro Cement Dome Structure

 

Link Here to Wikipedia: https://en.wikipedia.org/wiki/Ferrocement

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