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Ferrocement is used to construct relatively thin, hard, strong surfaces and structures in many shapes such as hulls for boats, shell roofs, and water tanks.
Ferrocement originated in the s in France and the Netherlands and is the origin of reinforced concrete. It has a wide range of other uses including sculpture and prefabricated building components.
The term "ferrocement" has been applied by extension to other composite materials , including some containing no cement and no ferrous material.
The " Mulberry harbours " used in the D-Day landings were made of ferrocement, and their remains may still be seen at resorts like Arromanches.
Cement and concrete are used interchangeably but there are technical distinctions and the meaning of cement has changed since the mid-nineteenth century when ferrocement originated.
Ferro- means iron although metal commonly used in ferro-cement is the iron alloy steel. Cement in the nineteenth century and earlier meant mortar  or broken stone or tile mixed with lime and water to form a strong mortar.
Ferro-concrete is the original name of reinforced concrete armored concrete known at least since the s and in it was well described in London's Society of Engineer's Journal  but is now widely confused with ferrocement.
Lambot patented his boat in but the patent was granted in Belgium and only applied to that country. At the time of Monier's first patent, July , he planned to use his material to create urns, planters, and cisterns.
These implements were traditionally made from ceramics , but large-scale, kiln-fired projects were expensive and prone to failure.
In , Monier expanded his patents to include bridges and designed his first steel-and-concrete bridge. The outer layer was sculpted to mimic rustic logs and timbers, thereby also ushering faux bois fake wood concrete.
In the first half of the twentieth century Italian Pier Luigi Nervi was noted for his use of ferro-cement, in Italian called ferro-cemento.
Ferro concrete has relatively good strength and resistance to impact. When used in house construction in developing countries, it can provide better resistance to fire, earthquake, and corrosion than traditional materials, such as wood, adobe and stone masonry.
It has been popular in developed countries for yacht building because the technique can be learned relatively quickly, allowing people to cut costs by supplying their own labor.
In the s through 's, it became popular in the United States as a construction and sculpting method for novelty architecture , examples of which are the Cabazon Dinosaurs and the works of Albert Vrana.
The desired shape may be built from a multi-layered construction of mesh, supported by an armature, or grid, built with rebar and tied with wire.
For optimum performance, steel should be rust-treated, galvanized or stainless steel. During hardening, the assembly may be kept moist, to ensure that the concrete is able to set and harden slowly and to avoid developing cracks that can weaken the system.
Steps should be taken to avoid trapped air in the internal structure during the wet stage of construction as this can also create cracks that will form as it dries.
Trapped air will leave voids that allow water to collect and degrade rust the steel. Modern practice often includes spraying the mixture at pressure a technique called shotcrete or some other method of driving out trapped air.
Older structures that have failed offer clues to better practices. In addition to eliminating air where it contacts steel, modern concrete additives may include acrylic liquid " admixtures " to slow moisture absorption and increase shock resistance to the hardened product or to alter curing rates.
These technologies, borrowed from the commercial tile installation trade, have greatly aided in the restoration of these structures.
Chopped fiber could inhibit good penetration of the grout to steel mesh constructions. This should be taken into consideration and mitigated, or limited to use on outer subsequent layers.
Chopped fibers may also alter or limit some wet sculpting techniques. The economic advantage of ferro concrete structures is that they are stronger and more durable than some traditional building methods.
In India , ferro concrete is used often because the constructions made from it are more resistant to earthquakes.
In the s, designers adapted their yacht designs to the then very popular backyard building scheme of building a boat using ferrocement.
Its big attraction was that for minimum outlay and costs, a reasonable application of skill, an amateur could construct a smooth, strong and substantial yacht hull.
A ferro-cement hull can prove to be of similar or lower weight than a fiber reinforced plastic fiberglass , aluminum , or steel hull. The advantages of a well built ferro concrete construction are the low weight, maintenance costs and long lifetime in comparison with purely steel constructions.
Especially with respect to the cementitious composition and the way in which it is applied in and on the framework, and how or if the framework has been treated to resist corrosion.
When a ferro concrete sheet is mechanically overloaded, it will tend to fold instead of break or crumble like stone or pottery. Dezember DE 8 Gold 16 Wo.
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