Pre-Cast FC Channels

The building system uses pre-cast ferrocement 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.

Ferrocement 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.

FC Channels are pre-cast shell units made with rich cement mortar (1:2) 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).

Advantages:

• Ferro-cement channel roof provides light weight roofing – 60% reduction in dead weight as compare to RCC
• Pre-casting of roof leads to substantial reduction in construction time
• 30% saving in cost possible because of reduction in steel quantity and elimination of coarse aggregates and shuttering
• Creates employment as the roof components can be locally produced and delivered through micro level enterprise
• Much better quality control can be maintained during pre-fabrication
• Versatile technology – w.r.t profiles of roofing channels (subject to structural design)
• Double layered stacking of channels is possible, if stack area in site is less