FERRO

CEMENT
ROOFING

CONCEPT
The building system uses pre-cast Ferro cement roofing channels of a segmental arch profile which are placed adjacent to each other and spanning
over two supports. After partly filling the valley between channels with concrete, the channels form an idealized T-beam and are able to carry the load
of a roof / floor. Ferro cement comprises of a uniform distribution of reinforcement by use of chicken wire mesh and welded mesh encapsulated in
rich cement mortar, thereby achieving significant reduction in both steel reinforcement and dead weight of roof. This composition provides a more
uniform distribution of strength as compared to RCC.
A Ferro cement roof channel is a longitudinal element, semi -cylindrical shaped. It is easy to construct, uses less cement and steel than a conventional
RCC roof and is also cheaper .During the installation process the roof channel is lifted into place and can immediately be joined together in order to
provide a shelter, a roof or a floor s lab.
The following document gives a detailed description of the manufacturing process of the most common and tested roof channel developed by the
Auroville Building Centre.

INTRODUCTION

Providing shelter to an ever increasing population is a challenge which cannot always be solved with the help of conventional available building
materials like bricks and concrete. Although these two materials have a proven Track record, they are becoming increasingly expensive and out of
reach for many users.
Ferro cement roof channels can be a solution as a roofing system for a wide variety of building situations.
The technique consist of making a mud mould on which the Ferro cement roof channel is cast, left overnight, demoded within the next few days,
cured and finally installed and finally installed and joined in suit at the required site.

ADVANTAGES
Less use of cement and steel for any given section compared with RCC, with a corresponding reduction in self weight.
A major reduction in cost expenses compared to RCC.
An easy manufacturing process, requiring only one mason and a mason helper.
A simplified and cheaper installation practice compare to RCC
The technique requires neither scaffolding, shuttering, nor a concrete mixer or a vibrator.

DISADVANTAGES
? The need of a casting space and working area to prefabricate the elements and cure them, this may be difficult or
expensive, especially in an urban setting.
? The need for strict control to ensure quality product
? The need for a proper applied curing method, usually overlooked in many building construction activities
? If the elements are not manufactured on the site they will have to be transported, which adds to the cost.
? Care should be taken not to damage the elements during transportation.

COMPONENT
Pre-cast Ferro cement Channels
FC Channels are pre-cast shell units made with rich cement mortar (1:2 to 1:3) and reinforcement
consisting of a continuous layer of chicken mesh with steel bars provided at two ends of the
channel.
These shell units are cast either manually on a masonry mould or mechanically on steel moulds
mounted on table vibrator. The channels are supported on ends either on load bearing masonry or
on a frame structure (RCC or steel).
Restraining Beams
Any lateral moment and deflection of FC Channel gets balanced by thrust of adjacent channel. In
order to balance the channel movement at ends, restraining beams must be provided to prevent
differential movement of FC roof in case of any instability in the support structure. The restraining
beam will be a part of RCC bands required for structural strengthening, especially in disaster prone
areas.
Concrete Filling
After the Channels have been placed side by side, they are joined together with a concrete infill of
at least M15 grade (1:2:4) laid to 150 mm thickness. This concrete completes the T-beam structural
action of the FC Channels and creates a basic roof. In case of an intermediate floor, the remaining
portion of the valley can be filled with lean concrete, brick jelly lime concrete or light-weight
material and finished with a floor.

COMPONENT
Pre-cast Ferro cement Channels
FC Channels are pre-cast shell units made with rich cement mortar (1:2 to 1:3) and reinforcement
consisting of a continuous layer of chicken mesh with steel bars provided at two ends of the
channel.
These shell units are cast either manually on a masonry mould or mechanically on steel moulds
mounted on table vibrator. The channels are supported on ends either on load bearing masonry or
on a frame structure (RCC or steel).
Restraining Beams
Any lateral moment and deflection of FC Channel gets balanced by thrust of adjacent channel. In
order to balance the channel movement at ends, restraining beams must be provided to prevent
differential movement of FC roof in case of any instability in the support structure. The restraining
beam will be a part of RCC bands required for structural strengthening, especially in disaster prone
areas.
Concrete Filling
After the Channels have been placed side by side, they are joined together with a concrete infill of
at least M15 grade (1:2:4) laid to 150 mm thickness. This concrete completes the T-beam structural
action of the FC Channels and creates a basic roof. In case of an intermediate floor, the remaining
portion of the valley can be filled with lean concrete, brick jelly lime concrete or light-weight
material and finished with a floor.

RESOURCE
Material and labor requirement for construction of a FC channel roof of
size 12 x15

DETAIL

DETAIL