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.