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TARA Ferrocement Roofing Technology |
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TARA
Ferrocement technology package for roofing uses state of-the-art design
principles to manufacture reinforced shells.
Commonly called channels they
are produced on specially designed vibrating tables and profiled moulds. The
production system is uniquely tailored to provide special end details,
consistent shape and thickness; all crucial for high performance the
channels made with an optimised proportion of cement, sand and water. They
have a very high density, are impervious to penetration of water and provide
high structural strength. Ferrocement roofing technology offers a viable
alternative to conventional flat roofing systems such as reinforced cement
concrete, reinforced brick cement, sand stone, etc. in both rural and urban
areas of the country.
Product
Ferrocement roofing channels have a uniform segmental profile; they are 2.5
cm thick and 83 cm wide. Maximum length of
mechanically produced channels
can be upto 6 metres.
Ferrocement roofing channels are manufactured using designed mix of cement, sand and water to give high strength mortar that is reinforced with a layer of galvanised iron chicken wire mesh of 22 gauge and tor steel bars of 8-12 mm diameter provided in the bottom nibs of the channel. Ferrocement roofing channels can be safely transported for the application after a curing period of 14 days.
Brief production
process
The mechanised system of production uses a vibrating table and profiled
steel shell moulds. The production yard consists of a vibrating table
positioned under a gantry system 6.5mts in width the gantry is fitted with a
chain and a pulley system for ease of handling of cast moulds. A production
team consisting of 2 mason, 12 unskilled workers and a supervisor can
produce upto 15 channels of 3.0-m length each in 8 hours operation.
The moulds are cast using the designed mortar and the filled moulds are lifted from the vibration table using specially designed lifting frame and steel tongs. Before demoulding, these moulds are kept undisturbed for 24 hours till the freshly cast channels achieve minimum strength. Finally these channels are stacked for water curing for minimum 14 days before they can be used for construction.
Advantages of TARA Ferrocement channels
| ● | Fast construction – prefabricated channels enable to construct a roof in just 3 days |
| ● | No shuttering required, unlike in-slab slab casting |
| ● | 30% cost saving over RCC roofing |
| ● | Less dead load on the walls |
| ● | High strength to weight ratio |
| ● | Appealing aesthetics - elegant profile and uniform size |
Areas
of Application
Ferrocement roofing channels,
offer unmatched speed of construction and offers a vast range for flat roof
application.
| ● | Residences |
| ● | Primary schools, and other community buildings |
| ● | Porticos, verandahs and garages |
| ● | Industrial sheds, Workshops and godowns |
| ● | Farm houses and semi-covered structures |
Development Status
Commercialized
Technical Data
| Specifications of the channel | Length - 3.05m and 4.6m (maximum upto 6.05 m) Clear bay width 0.75m, total bay width 0.83m Profiles as per rise of the arch - 290mm and 150mm |
| Annual production | 3000 No. of Ferrocement channels |
| Land requirement | Total 2500m2 for casting, demoulding , curing, stacking and movement space,250 m2 of covered working space |
| Electricity requirement | 10 KVA |
| No.of jobs created | 10 (1 supervisor, 1 skilled, 8 unskilled) |
Economic Data
| Infrastructure cost for office and workshop (includes: Working shed, office space, cement godown, facilities-electricity and water) | Rs 240,000 |
| Equipment (with 1machine, 10 No moulds) (vibrating table with vibrators, moulds, lifting frame, a pair of tongs and transfer trolley) | Rs 384,000 |
| Gantry system cost (in a mechanized system) | Rs 125,000 |
| Transportation and insurance (in India | Rs 12,000 |
| Installation and know how transfer | Rs 50,000 |
| Total (package with hydraulic machine) | Rs 8,11,000/- (US$ 16,220) |
| These cost do not include cost of land, as it varies considerably from place to place) | |
Business
Ferrocement technology is a highly
profitable business for small scale building material producers and
construction companies. To start the enterprise with a set of 10 moulds,
require a total investment of Rs. 8,11,000/-. This semi-mechanised
production system assures a turnover of Rs 29,50,000/- per annum, which
yields more than 20% recovery on the investment within one year of
operation. Moreover, within 2 yrs of operation, by investing into 5 extra
moulds, which cost Rs 1,45,000, the turnover of the production unit can be
increased by 1.5 times, producing 15 channels per day. This increase in
productivity involves minimal increase in labour requirement without any
investment on infrastructure. The equipment is supplied by TARA (Technology
and action for Rural Advancement), a leading sustainable technology
marketing organisation
Transfer forms
Equipment, Turnkey basis
For further
information, please contact:
Mr. Subroto Roy
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