Ferrocement, a robust form of reinforced concrete with wire meshes evenly distributed, boasts unparalleled strength and versatility compared to other thin construction materials. Originating in 1848 with Joseph Louis, it initially faced limited adoption due to production inefficiencies. However, with modern tools and techniques, ferrocement is now widely embraced.
The fabrication of ferrocement hinges on various factors, including the application’s nature, machinery availability, skill, and overall labor cost. Molds can also be employed in the preparation process, ensuring high-level control criteria for proper encapsulation of wire mesh layers with mortar or concrete matrix. Let’s delve into the distinct methods of constructing ferrocement structures.
In this method, multiple layers of wire mesh are tied to reinforcing bars forming a skeleton steel frame. The framework is then welded into the desired shape. Mortar is applied, penetrating through the mesh layers until excess mortar appears on the other side. After pressing back the excess, the remaining mortar is smoothed for a polished finish. The skeletal steel acts as spacer rods, adding weight but not strength to the structure.
In this approach, wire mesh layers are tied or stapled and positioned against a closed mold’s surface. Mortar is then applied from one side. While separating the mold is optional, it can be done using release agents. This method allows the use of mesh reinforcement without bars or rods, requiring plastering from one side only.
The integral mold, integral to the structure, features a semi-rigid framework with mesh layers or insulating materials like polyurethane. Mortar can be applied from one or both sides. To enhance quality, additional mesh layers with mortar can be added after the initial setting, ensuring a firm bond between the mold and later layers.
Similar to the closed mold method, mortar is applied through one side of mesh layers and rods to an open mold made of wooden strips. The mold is coated with a release agent or covered with polyethylene sheeting, creating a non-rigid, transparent mold. This facilitates mold removal, allowing observation and repair during the mortar application process.