Water Tank

Large Ferro-Cement Water Tank
Design Parameters and Construction Details
Technical Support Section

Division of Operational Support
July 2006
Table of Contents
I
Introduction ..............................................................................................4
II
Basis for Design and Underlying Concepts...........................................6
III
Prototype Construction and Test ...........................................................7
IV
Construction Steps ..................................................................................9
List of Annexes
VI Material Specifications ..........................................................................16
VII Bill of Quantities Summary Sheet......................................................17
VIII Detail Calculation Sheet .............................. Error! Bookmark not defined.
Detail Drawings for Three Set of Tanks (45, 75 and 90 cu.m.)
List of Figures
Figure 1. Wall Cross-section on a Horizontal Plan in Skeletal/Armature
Method of Construction ..............................................................................8
Figure 2. Tank after One Week of Filling...........................................................9
Figure 3. Tank after Two Weeks of Filling ........................................................9
Figure 4. Preparation of Foundation ...............................................................10
Figure 5. Preparation of Lean Concrete Base ................................................10
Figure 6. Placement of Rebar for Base Slab...................................................11
Figure 7. Casting of Concrete Base Slab........................................................11
Figure 8. Vertical Reinforcement and Wall Stiffeners....................................11
-2Large Ferro-Cement Water Tank UNHCR, July 2006
Figure 9. Temporary Access ............................................................................11

Figure 10. Inlet/Outlet Opening........................................................................11
Figure 11. Overflow Opening ...........................................................................12
Figure 12. Fixed Wire Mesh..............................................................................12
Figure 13. Fixing of Central Column ...............................................................12
Figure 14. Plastering of Wall............................................................................13
Figure 15. Fixing of Roof Trusses (Stiffeners) ...............................................14
Figure 16. Placement of Roof Reinforcements...............................................14
Figure 17. Roof Opening ..................................................................................14
Figure 18. Temporary Formwork for Roof ......................................................15
Figure 19. Plastering of Roof ...........................................................................15
Figure 20. Temporary Opening ........................................................................15
Figure 21. Finished Ferro Cement Tank..........................................................15
Introduction
UNHCR, the United Nations refugee organization, is mandated by the United Nations to
lead and coordinate international action for the world-wide protection of refugees and the
resolution of refugee problems. UNHCRs primary purpose is to safeguard the rights and
well-being of refugees.
Protection and material relief are interrelated. UNHCR can only offer effective legal
protection if a person's basic needs shelter, food, water, sanitation and medical care
are also met. The agency therefore coordinates the provision and delivery of such items
and has designed specific projects for vulnerable women, children and the elderly who
comprise 80 percent of a normal' refugee population.
Provision of clean water for domestic purposes is among the core services of UNHCRs
relief programmes designed for its beneficiaries, often delivered through the
implementing partners. A water supply system constitutes a set of components, which
are meant for specific functions abstraction/collection, treatment (if required),
conveyance/transmission, storage for balancing and/or service, distribution, disposal (of
waste water) and storage at household. Several factors govern effectiveness of a water
supply system. One of them is the choice of technologies and skills that are sensitive
and appropriate to local know-how and expertise.
Storage of water between the source and the distribution points, whether for a balancing
or service purpose, is one of the essential functions in a water supply system, and is the
only means of ensuring a constant availability of water to the beneficiaries in a given
camp/settlement site. In a refugee operation, its role becomes more important as the
amount of water available from the sources is often limited and less reliable, and hence
a substantial storage facility would be needed to meet various needs be it during an
emergency, a stabilized or a returnee situation.
Water storage facilities or tanks commonly used by UNHCR and other humanitarian
agencies include ground tanks (ponds, basins or reservoirs), masonry or reinforced
concrete tanks, collapsible fabric tanks (onion, bladder or pillow type), steel or plastic
tanks (pre-fabricated and modular type), standard water storage packs (Oxfam type) and
ferro-cement tanks. All these tanks have their relative advantages and disadvantages,
and therefore, their choice and application in a specific operation would vary according
to the analysis of a situation at the time of water system development planning.
Collapsible fabric tanks and standard water storage packs by virtue of their ease of
handling and rapid installation are found to be most useful in the initial stages of an
emergency operation. Apart from emergencies, UNHCR and other humanitarian
organizations however are often involved in many other operations which are
characteristically long-term in nature - for example, stabilized, protracted or
reintegration/local settlement programmes. In these situations, the choice of a
technology invariably would be governed by parameters which are different from the
ones used for short-term needs. Such criteria/parameters would include capital as well
as operation costs, ease of operation, durability/service-life, conducive to local knowhow/skills for repair/maintenance, availability of material locally, and environmentally
sound technologies and construction. All of these are basically linked to costeffectiveness, operational reliability and long-term sustainability.
Use of ferro-cement tanks, though it fulfills most of the criteria above, is still limited in
refugee operations. The reasons for this include inadequate knowledge about and/or
exposure to the technology (which is relatively new); lack of access to relevant userfriendly literature and difficulty in constructing large water tanks (> 40,000 litres).
What is Ferro-Cement technology?
Ferro-cement is essentially an extension of conventional reinforced cement concrete
(RCC) technology. As such, all the benefits attributed to use of RCC in construction
normally apply to ferro-cement as well. There are, however, other advantages that make
ferro-cement a preferred choice in many construction projects.
It is a thin-walled construction consisting of rich cement mortar with uniformly distributed
and closely spaced layers of continuous and relatively small diameter mesh (metallic or
other suitable material). Compared to other cement concrete structures, those made of
ferro-cement are light weight (use less material, and therefore, also environmentally
benign), tough, durable, crack resistance and can be made into virtually any shape. It is
a low technology construction in that it does not necessarily require highly skilled labour
and complex construction methods, sophisticated or heavy equipment or manufacturing
in a plant, and yet a good performance in construction can be achieved. Finally, it is
more economical than other concrete or masonry constructions and can easily be
repaired, if necessary.
In an attempt to promote the use of ferro-cement water tanks in UNHCR operations, a
research study was conceived on the basis of efforts initiated by the Office in Bhutanese
Refugee Programme in Nepal. UNHCR has engaged the services of the Asian Center
for Engineering Computations and Software (ACECOMS) and the International Ferrocement Information Center (IFIC) at the Asian Institute of Technology (AIT), Bangkok to
carry out this research study.
The main purpose of the study was in two folds:
Review the existing techniques used in ferro-cement construction and

develop/design large water tanks with capacities in the range of 40,000 to
100,000 litres, and that can easily be adopted in UNHCR operations.
Conduct a prototype test to ensure structural integrity, assess operational

performance, and prepare and document detailed drawings, bill of quantities,
and constructions steps.
This booklet summarizes the underlying design concept of improved large ferro-cement
water tanks, and presents easy-to-follow construction details with relevant drawings, bill
of quantities and necessary guidance. The goal is for the practitioner engineers in the
frontline could use it without much difficulty and that the knowledge is widely shared and
applied in the field, both in the realm of humanitarian as well as development
programmes.
II
Basis for Design and Underlying Concepts
As a prelude to the research study, besides literature surveys and field visits to refugee
camps in Jhapa/Nepal, the research team undertook an evaluation of various water tank
systems. Main features for comparison included:
Cost
Constructability
Skill and technology requirements
Availability of materials
Short and long term performance and
Adaptability.
After evaluating several water tank systems ferro-cement was found to best serve most
of UNHCRs requirements, except in an emergency operation. Initially, two options were
considered for further design and prototype testing.
Option 1: Cast-in-place Ferro-cement Tanks
Option 2: Pre-cast Ferro-cement Tanks
For the sake of brevity, the following paragraphs outline only the basis of design and the
key features considered in the process without dwelling much on the analytical and other
details involved.
To start, a comprehensive modelling procedure and analysis of a typical tank was
carried out with an objective to understand the structural behaviour of the tank, to
replicate and predict its response to various loads (e.g. hydrostatic), and to evaluate the
serviceability state. A full three-dimensional finite element model (FEM) of the tank,
including the associated components, was constructed and analyzed using SAP2000
software. Both the wall and the roof were modelled using shell elements.
Results of analysis primarily contain the deformation and the stresses caused by the
applied loads. These results were used for checking the safety and serviceability
requirements of the tank. Upon evaluating the results, it was found that the maximum
stresses under full water load condition are within the acceptable (safe) limits. In other
words, the proposed system is safe for full water loading and reasonable live load on the
roof.
A number of books, research documents, technical publications, existing design codes,
guidelines and recommendations dealing with ferro-cement and laminated cementitious
composites were extensively consulted. The final design was based primarily on Ferrocement Model Code (Building Code Recommendations for Ferro-cement (IFS-10-01),
January 2001). In addition, the performance of more than 20 ferro-cement water tanks
built under the technical supervision of IFIC over a period of 10-15 years was evaluated
to identify the system offering the most cost-effective and desirable short and long-term
performance.
The basic design followed the concepts and general principles in current use in
structural engineering, particularly for reinforced and pre-stressed concrete structures.
The structure was designed to satisfy a number of limit states, where a limit state is
defined as the boundary between acceptable and unacceptable performance.
Practical design guidelines to ensure good serviceability of ferro-cement structures were
based on allowable stresses under maximum service load, maximum crack width,
fatigue life, durability and corrosion, and deflection limitations. Accordingly design
parameters were defined for:
The cover to the first layer of reinforcement;
Thickness of wall and roof members;
Size of mesh opening;
Skeletal reinforcement depth, volume fraction of the reinforcement and

specific surface of reinforcement;
Number of mesh layers, mesh opening area and wire diameter; and
Fineness of matrix (mortar).
Though the final design was based primarily on the relevant Ferro-cement Model Code,
the skeletal reinforcement and wire mesh requirements computed based on the code
were modified and verified experimentally. The code based calculation showed that
more than 4 layer of wire mesh need to be provided but this was reduced to 2 by taking
into account the contribution of skeletal steel and providing additional stiffeners (steel
channels and the roof trusses). This new concept introduced in the present design
distinguishes the proposed large ferro-cement water tank from the other. The
proposed design significantly reduces the cost of the tank without affecting its structural
integrity, safety and performance. The finite element analysis was also used to verify the
adequacy of the design.
III
Prototype Construction and Test
There are several methods for the analysis, design and construction of ferro-cement
structures. The main difference among these methods is related to the strength
contribution of the skeletal steel. Most ignore the strength contribution of skeletal steel.
But based on several tests carried out both IFIC and AIT, it has been found that this
results into a very uneconomic design. Rational analytical methods for computing the
strength of the ferro-cement structures for tension, bending, shear and their combined
effects that take into account the contribution of all the skeletal, mesh, and mortar are
not available. Hence, the only way to determine strengths related to these forces is
through experimental or prototype tests.
The three main objectives of the prototype testing of the tank are to:
Study its constructability aspects;
Verify the strength requirements; and
Study its water permeability (tightness) and initial stage performance.
Among several methods available for construction, the Skeletal/Armature method

(shown in the sketch below) was chosen for its obvious advantages no framework
required, good mortar penetration can be achieved, easy to patch-up all areas from both
sides. The armature method is a framework of tied reinforcing bars (skeletal steel), wires
or strands, to which layers of reinforcing mesh are attached on each side. Mortar is then
applied, preferably from one side, and forced through the mesh layers until a slight
excess appears on the other side. This excess is then pressed back through the
armature and struck off as finishing.
Figure 1. Wall Cross-section on a Horizontal Plan in Skeletal/Armature Method of Construction
The strength requirements were verified as follows:

Strength of walls: The strength of the walls was verified by filling the tanks progressively
with water over a span of 5 days (20% at a time) and observing the performance at each
stage. No unusual behaviour was observed for the first month after filling the tanks to
their full capacity.
Strength of Roof: The roof was loaded with over two tons of cement bags for a period of
half an hour after a month following completion of the tank. The capacity was also
verified by applying live load, over 14 persons (AIT students) standing on the roof during
a site visit.
The most effective and natural way to study the water tightness of a tank is to fill it with
water and observe whether or not there is any leakage. With this objective, the tank was
filled with water progressively over a span of 5 days until sufficient overflow water
obtained from the overflow pipe near the top. Some seepage was observed during the
first week of filling but dried up within few days. Seepage in the first week of filling is
expected, as it is the inherent property of ferro-cement structures. The chemical reaction
of the remaining cement mortar ingredients with water (hydration) causes the expansion
of such particles, thereby reducing the permeability of the wall. We can also observe
white patches (effervescent) of the products of the chemical reaction on the exterior
surface of the tank. However, they vanished within couple of weeks as the cement
attains proper setting with the progress of time.
Figure 2. Tank after One Week of Filling
IV
Figure 3. Tank after Two Weeks of Filling
Construction Steps
The following paragraphs outline the easy-to-follow details on the how to proceed with
the construction of the cast-in-place ferro-cement tank. They are separated into three
sections: foundation, wall and roof. These should be read in conjunction with the
Sections on Material Specifications and Drawings, as that is where dimensions and
quantities are provided.
Foundation
Step 1: Selection of Site: The site should be located in an area higher than its
surroundings. The other considerations include the sources of water supply, areas in
which the water is to be distributed, possibility of flooding, and practical aspects of
construction. The final decision should be taken by a qualified engineer.
Step 2: Site Clearance: The site must be cleared, with loose surfaces compacted and
levelled properly. The area should be protected or fenced, if necessary.
Step 3: Preparation of Foundation: The type of foundation required may differ
depending upon geographical locations, soil condition, and size of the water tank. The
design should be carried out by a civil or geotechnical engineer. For the prototype,
the foundation consists of compacted soil and sand up to 0.5 m above the existing
ground level. To facilitate the retention and compaction and provide additional strength,
concrete hollow blocks with vertical bars along the circumference at about 20-30 cm
centre to centre can be used. However, other methods that would serve the same
purpose can also be employed depending on the requirements of the site and the
availability of type of local construction material.
Steps to prepare the foundation
1) Mark the location of the foundation perimeter (circular ring).
2) Lay the blocks.
3) Insert the vertical bars (dia. 6 or 9mm, 20-30 cm c/c); fill the holes with
cement mortar.
4) Fill the space with soil/sand. At least top 10 cm should be filled with sand.
5) Compact the soil using a compacting hammer or other devices.
6) Wet the sand with water and compact.
Figure 4. Preparation of Foundation
Figure 5. Preparation of Lean Concrete Base
Step 4: Preparation of Lean Concrete Base: Lean concrete provides a level base and
water-tightening layer for the concrete slab to be cast upon. This layer should be laid
over the foundation. Generally, 5-6 cm thick lean concrete (typically a mix of 1: 3: 5 by
weight) is used.
Step 5: Preparation of Base Slab Reinforcement: There are two ways to prepare the
slab reinforcement: either at its final location or at a nearby location and then move to
the final place. In this prototype, two layers were prepared outside the tank area and
transferred by lifting. Generally 4 to 6 persons are required for moving and placing the
reinforcement.
Step 6: Laying Base Slab Reinforcement: The two layers of slab reinforcement were
placed in their final position. The distance between the layers can be controlled using
small separators made up of crushed concrete pebbles or pre-cast pieces.
Step 7: Erecting L-bars Along the Wall-Base Junction: L-shaped bars are used both
for strength and to improve constructability. It is difficult to fix the long vertical bars (1 to
2.5 m) to the base slab reinforcement at this stage. L-shaped bars being shorter/lighter,
it is easier to tie into base slab reinforcement. One or two tie wire pieces are required for
each L-shaped bar. If long vertical bars are fixed at this stage it is not convenient to pour
the concrete and go inside for levelling. It is always convenient to place at least two (the
top and bottom) circular rings and then fix the L-shaped bars as anchor bars.
Step 8: Placing Vertical Dowel/Fixing Plate/Bars for Central Column: Similar to the
L-shaped bars placed along the perimeter, 4-8 bars can be placed at the location where
the central column is to be erected. Alternatively a base plate with holes/bolts can be
fixed at this stage.
Figure 6. Placement of Rebar for Base Slab
Figure 7. Casting of Concrete Base Slab
Step 9: Casting the Base Slab: After fixing the rebar for slab, the central column and
the peripheral L-shaped bars, the slab can be concreted. The surface should be levelled
properly with trowel or smooth planks. The concrete (1:2:4 by weight) can be mixed at
the site or can be ordered from the ready-mix supplier.
Wall
Step 10: Erecting Vertical Reinforcement and Stiffeners for the Wall: As the water
pressure decreases with height, the amount of reinforcement required also varies with
height. Bars can be spaced tightly at the lower part and the spacing can be increased
with height. Therefore, there are vertical bars of two different lengths (but same
diameter) the first type extending only up to 1 meter from the base and the other type
extending up to the top of the wall with some additional length to bend into the roof (2.2
+ 0.3 = 2.5m). These bars are fixed with tie wire to the L-shaped base bars. It is
convenient to erect a few bars at first just enough to hold the topmost circular ring and
then only to erect the remaining vertical bars. The top and bottom rings now provide the
anchorage for the vertical bars.
Eight steel channels are used to provide
additional stiffness to the wall at every
45 degree angle. These channels are
placed with the hollow part facing
inward (ease for plastering). The height
of these channels will be equal to the
height of the wall. The eight shallow roof
trusses will be welded with these
channels at the top.
Figure 8. Vertical Reinforcement and Wall

Stiffeners
Step 11: Keeping Openings for Construction and Pipe Works: A temporary access
opening should be provided for the movement of the workers in and out of the tank
during construction. The size of the opening should be large enough for one person to
enter the tank. This opening will be plastered at the end.
Similarly, openings for inlet, outlet, overflow and ventilation pipes are required at this
stage. It is not recommended to make holes when plastering has been completed. If any
other fixings are required they should be added at this stage.
Figure 9. Temporary Access
Figure 10. Inlet/Outlet Opening
Figure 11. Overflow Opening
Opening
Step 12: Fixing the Wire (Chicken) Mesh (WM1 and WM2): Chicken mesh comes in
rolls. Normally two layers of chicken mesh are used. The mesh is wrapped around the
wall reinforcement and fixed with tie wire at a few locations. It is convenient to start from
the bottom and move upward. About 10 cm of overlapping is recommended at
discontinuous ends. Both inner and outer layers should be placed before starting the
plastering.
Figure 12. Fixed Wire Mesh
Figure 13. Fixing of Central Column
Step 13: Preparation and Fixing of the Central Column: There are several options for
the selection, preparation, and fixing of central columns. The central column can be
made up of concrete alone, galvanized iron (GI) pipe filled with concrete, a GI pipe
alone, properly painted steel pipe/tube, or ceramic pipe filled with mortar. The main
considerations for selection are strength, corrosion protection and workability. The
mortar filling of the pipe or tube may or may not contain the reinforcement.
There are two methods for preparation: either the column can be prepared completely
outside and fixed at its final position or alternatively, all the work, including placement of
rebar and fixing of the top plate, can be performed when it is erected.
NOTE: Considering several factors, it is strongly recommended to finish the column to

the ready-to-fill stage before erecting. The dowel bars coming out of the base slab at the
slab centre should be encased by the bottom end of the pipe. If required, some
temporary support may be provided. The plate at the top of the column may be fixed
before or after erection. It is generally welded with the column rebar at top.
Step 14: Plastering the Wall: Once wall reinforcement and central column erection
have been completed, the wall is ready for plastering. The first step for plastering is the
preparation of the mortar (sand and cement only, ratio 1:2) with a workable consistency
(limiting water cement ratio in the range of 0.35 to 0.45 by weight gives the optimum
results, and helps to attain low porosity of the mixture).
It is easier to work the inside face first
and then the outer face. The plaster is
applied by the mason from the inside,
pushing the mortar into the layers of
mesh, with a helper holding a sheet of
plywood/wooden
plank
on
the
corresponding area outside. Therefore
the plastering of the first face requires at
least two persons, one to hold the
plywood/wooden plank at outer face,
and a mason to plaster from inside.
However, once one face has been
completed, the already completed side
acts as a wooden plank for the other
face, thus eliminating the need for
temporary support on the opposite face.
Special care should be taken while
plastering around the edges, rings and
openings so as to avoid leaks in the

future.
Figure 14. Plastering of Wall
Roof
Step 15: Preparation of Roof Shallow Truss: Eight roof trusses of about 10 cm depth
made up of 9mm (top and bottom) and 6 mm (vertical and diagonal) welded bars are
used to stiffen the roof. Typically the fabrication of a truss involves cutting, bending and
welding the top and bottom chords vertically and diagonally.
16: Fixing Roof Trusses (Roof Stiffeners): The roof-stiffening trusses are welded with
the top of C-channels in the wall at the lower end and with the column top base plate at
the other end. While cutting bars for the trusses, additional lengths are required to
facilitate welding with the C-channels. These trusses are braced laterally by similar
trusses at their mid-length, forming an octagon. If the welding facility is difficult to
mobilize to the site, a simpler method like nuts and bolts or other hooking mechanisms
can substitute the welding needs.
Figure 15. Fixing of Roof Trusses (Stiffeners)
Step
17:
Placement
of
Roof
Reinforcements: Once the main and
bracing roof trusses have been placed,
the circumferential and radial bars for
the roof must be placed. Some of the
radial bars can be curtailed at midlength along the roof surface. The
portions of the vertical bars extending
above the height of the wall are bent
into the roof.
Figure 16. Placement of Roof Reinforcements
Step 18: Providing Openings in the

Roof: At least one manhole should be
constructed as access to the tanks
interior for inspection, cleaning and
repair purposes. An additional hole may
be constructed for fixing inlet or
ventilation pipes. An additional bar of
9mm can be placed along the perimeter
of the opening.
Figure 17. Roof Opening
Step 19: Plastering of Roof Trusses: The roof trusses perform basically two functions:
during construction they act as support for the wet roof surface and, throughout the life
of the structure, they act as stiffeners. Therefore these trusses (main and bracing) are
plastered before plastering the roof surface. The process of plastering these trusses is
similar to that for walls.
20: Temporary Formwork for Plastering Roof Surface: Similar to the walls, the
plastering of the roof is also carried out from the top against a sheet of plywood/wooden
plank placed on the working area underside. This requires a temporary formwork for
supporting the wooden plank/plywood. A plank/plywood may be supported by 2-3 props.
Figure 18. Temporary Formwork for Roof
Figure 19. Plastering of Roof
Step 21: Plastering the Roof Surface: As explained previously, plastering the roof is
also carried out from the top against a sheet of plywood/wooden plank placed on the
working area underside. It is highly recommended to plaster the area near the truss first
and progress sideways.
Step 22: Plastering the Temporary Openings: These
areas should be the last items to be plastered. Now the
roof opening should be used an access. One person
should enter into the tank through the permanent
opening in roof to assist plastering. The temporarily
bent bars at the openings should be straightened before
closing with mesh and plastering.
Step 23: Finishing the Surface: The excess mortar
and uneven surfaces should be brushed off to finish the
surface. Finally, the exterior of the tank should be
painted with a cement coat of a preferred shade, and the
periphery of the plinth should be back-filled with a layer
of grass-turf on the top and drainage developed to avoid
accumulation of rainwater.
Figure 20. Temporary Opening
Figure 21. Finished Ferro Cement Tank

VI
Material Specifications
MATERIAL
Cement
COMMENTS
Use ordinary Portland cement Type I or II for tropical countries and Type II for
cold climates.
Sand
Use well graded sand. Sand that is too fine or too coarse is not suitable.
Separate sand from stone using6.4 mm (1/4 inch) mesh screen.
No organic or chemical impurities. If quality is in doubt, wash with clean water.
Desirable sand grading as follows
Sieve
Percent Passing
3/8 in. (9.5 mm)
100
No. 4 (4.75mm)
95 to 100
No. 8 (2.36mm)
80 to 100
No. 14 (1.18mm)
50 to 85
No. 30 (600m)
25 to 60
No. 100 (150m)
2 to 10
Water
Water fit for drinking is suitable. Salty water should never be used.
Wire Mesh
Must be easy to handle and flexible enough to be bent around corners.

Galvanized wire mesh is preferred as it is less likely to rust or corrode.
Use 0.5 mm to 1.00 mm diameter with 10 mm to 25 mm mesh opening.
Free from grease, oil, rust and anything that might reduce bond.
Skeletal Steel
Free from grease, oil detergents, organic matter and cracks of blow holes.
Bars are acceptable if no cracks appear after the following field test:
Bend bar into a U shape and then straighten it out. Bend it again into a U
shape in the opposite direction and straighten it out.
Grade SR24: yield strength = 2400-2600 ksc
Steel Channel
Free from grease, oil detergents, organic matter, cracks of blow holes
Size 7.50 mc x 3.75 cm (height x width)
Grade Fy = 2400-2600 ksc (34-36 ksi) and FU = 4000-4500 ksc (57-64 ksi)
Tie Wire
Use annealed (soft) galvanized wires of 24 or 26 gauge. Cut pieces of wire

from meshes could also be used for tying.
Mix Proportions
Lean Concrete
= 1:4:8 (Cement: Sand: Aggregate by weight)
Slab Concrete
Mortar for wall and roof = 1:2:0.4 (Cement: Sand: Water by weight)
VII
Bill of Quantities Summary Sheet

Quantity
Items
Unit
45 cu. m.
75 cu. m.
90 cu. m.
14
21
25
pieces
150
280
195
Cement
kg
3267
4553
5072
Fine Sand
4.26
6.0
7.0
Coarse Aggregate
5.0
7.0
8.14
Reinforcement Bar 6 mm
164
242
279
Reinforcement Bar 9 mm
1452
1976
2375
Steel Channels (7.5 cm x 3.75 cm)
18
18
18
Wire Mesh
123
168
191
GI Pipe
2.7
2.7
2.7
Steel Plate
0.09
0.09
0.09
Coarse Sand for Basement

Hollow Blocks
Note: Plumbing fixtures (inlet, outlet, overflow and flush-out), cement paint on the exterior,
backfill, grass turf and drainage around the tanks to be added as appropriate. Construction
period is three to four weeks for about 60-75 man-days of skilled labour.
VIII Detail Calculation Sheet

Basement
Item/Shape
Dimensions (m)
3
45 m
a = 6.30
b = 0.45
Coarse Sand
70 m
a = 7.70
b = 0.45
Material
3
90 m
a = 8.30
b = 0.45
Quantity
3
Coarse
Sand
Unit
3
45 m
14.0
70 m
21.0
90 m
25.0
150
180
195
pieces
250
0.25
0.10
10.0
300
0.30
0.12
12.0
325
0.33
0.13
13.0
kg
3
m
3
m
m
Hollow Blocks (0.20 m x 0.40 m)
Hollow
Blocks
(3 rows)
Cement
Sand
Water
RB 6 mm @
0.40 m
(L = 0.20 m)
Base Slab
Item/Shape
Dimensions (m)
3
Lean Concrete
a
Material
3
Quantity
70 m
576
1.25
2.09
0.41
Unit
90 m
648
1.41
2.35
0.46
45 m
a = 6.30
b = 0.05
3
(1.6 m )
70 m
a = 7.70
b = 0.05
3
(2.4 m )
90 m
a = 8.30
b = 0.05
3
(2.7 m )
a = 6.30
a = 7.70
a = 8.30
RB 9 mm
(304 m/
1 layer)
608
880
1120
a = 0.40
b = 0.30
(168
pieces)
a = 0.40
b = 0.30
(212
pieces)
a = 0.40
b = 0.30
(232
pieces)
RB 9 mm
(0.7 m/
1 piece)
118
149
163
a = 6.30
b = 0.12
3
(4.0 m )
a = 7.70
b = 0.12
3
(5.6 m )
a = 8.30
b = 0.12
3
(6.5 m )
Cement
Sand
Stone
Water
1280
1.80
3.56
0.75
1792
2.52
5.00
1.05
2080
3.00
5.79
1.22
kg
3
m
3
m
3
m
Cement
Sand
Stone
Water
45 m
384
0.84
1.40
0.27
kg
3
m
3
m
3
m
ST1 & SB1 (RB 9 mm @ 0.20 m:

2 Layers)
a
SL1 (RB 9 mm @ 0.10 m)

b
Concrete
a
Ferro-cement Wall
Item/Shape
Dimensions (m)
3
Material
3
Quantity
Unit
RB 9 mm
(2.5 m/
1 piece)
a = 1.00
(84
pieces)
a = 1.00
(106
pieces)
a = 1.00
(116
pieces)
RB 9 mm
(1.0 m/
1 piece)
84.0
106
116
a=
0.0375
b=
0.075
a=
0.0375
b=
0.075
a=
0.0375
b=
0.075
C 7.0x3.75
cm
(2.2 m/
1 piece)
17.6
17.6
17.6
WH1 (RB 9 mm @ 0.20 m: 12 pieces)

a
a = 5.30
a = 6.70
a = 7.30
RB 9 mm
(16.7 m/
1 piece)
201
252
276
WM1 & WM2 (Chicken Mesh: 2

layers)
a=
16.70
b = 2.20
a=
21.00
b = 2.20
a=
23.00
b = 2.20
Chicken
Mesh
2
(37 m /
1 layer)
74.0
92
101
a = 5.30
b = 2.20
c = 0.03
3
(1.1 m )
a = 6.70
b = 2.20
c = 0.03
3
(1.4 m )
a = 7.30
b = 2.20
c = 0.03
3
(1.5 m )
Cement
Sand
Water
7110.7
2
0.70
0.29
905.80
0.91
0.37
970.50
0.98
0.39
kg
3
m
3
m
Steel channel (8 pieces)

b
90 m
290
90 m
a = 2.20
b = 0.04
c = 0.30
(116
pieces)
a
b
WV2 (RB 9mm@ 0.20 m)
70 m
265
70 m
a = 2.20
b = 0.04
c = 0.30
(106
pieces)
WV1 (RB 9 mm @ 0.20 m)

c
45 m
210
45 m
a = 2.20
b = 0.04
c = 0.30
(84
pieces)
a
Ferro-cement
a
c
Ferro-Cement Roof
Item/Shape
Dimensions (m)
3
Material
3
a = 1.50
(58
pieces)
RB 9 mm
63.0
80.0
87.0
a = 3.30
b = 0.10
a = 3.60
b = 0.10
RB 9 mm
(2.70m/
1 piece)
44.0
55.0
60.0
a = 2.60
b = 0.20
c = 0.10
a = 3.30
b = 0.20
c = 0.10
a = 3.60
b = 0.20
c = 0.10
RB 6 mm
( 3.7m/
1 piece)
30.0
38.0
40.0
a = 2.60
b = 0.10
a = 3.30
b = 0.10
a = 3.60
b = 0.10
Chicken
Mesh
2
(0.52 m /
1 piece)
5.0
6.0
6.0
RC1 (RB 6 mm @ 0.20 m)

a
a = 5.005.30
(13
pieces)
a=
6.306.70
(17
pieces)
a=
7.007.30
(18
pieces)
RB 6 mm
(1.6 16.7
m)
119
187
221
RM1 @ RM2 (Chicken Mesh: 2

layers)
a
a = 5.30
a = 6.70
a = 7.30
Chicken
Mesh
2
(22 m /
1 layer)
44.0
70.0
84.0
Ferro-cement
a = 5.30
b = 0.03
c = 0.50
3
(0.67m )
a = 6.70
b = 0.03
c = 0.50
3
(1.1 m )
a = 7.30
b = 0.03
c = 0.50
3
(1.3 m )
Cement
Sand
Water
433.49
0.44
0.18
711.70
0.72
0.29
841.10
0.85
0.34
kg
3
m
3
m
RD2 (RB 9 mm @ 0.40 m)

a
Upper and Lower Code for truss
(RB 9 mm: 16 pieces)
90 m
a = 3.60
(58
pieces)
a = 1.50
(42
pieces)
a = 1.50
(53
pieces)
a = 1.50
b = 0.10
70 m
175
Unit
90 m
209
RB 9 mm
70 m
a = 3.30
(53
pieces)
45 m
110
RD1 (RB 9 mm @ 0.40 m)
45 m
a = 2.60
(42
pieces)
Quantity
3
b
a
Bracing for truss (RB 6 mm: 8 pieces)
c
b
a
Chicken Mesh for truss (8 pieces)
a
c
b
a
Central Column
Item/Shape
Dimensions (m)
3
GI pipe (diameter = 0.15 m)
Material
3
Quantity
3
70 m
2.70
Unit
90 m
2.70
45 m
a = 2.70
b = 0.15
70 m
a = 2.70
b = 0.15
90 m
a = 2.70
b = 0.15
GI pipe
45 m
2.70
a = 2.70
a = 2.70
a = 2.70
RB 9 mm
11.0
11.0
11.0
a = 0.12
a = 0.12
a = 0.12
RB 6 mm
(0.38 m/
1 piece)
4.60
4.60
4.60
a = 0.40
b = 0.30
a = 0.40
b = 0.30
a = 0.40
b = 0.30
RB 9 mm
(0.70 m/
1 piece)
a = 0.30
b = 0.30
a = 0.30
b = 0.30
a = 0.30
b = 0.30
Steel Plate
0.09
0.09
0.09
a = 2.70
b = 0.15
a = 2.70
b = 0.15
a = 2.70
b = 0.15
Cement
Sand
Water
207
0.21
0.08
207
0.21
0.08
207
0.21
0.08
kg
3
m
3
m
b
a
CV1 (RB 9 mm: 4 pieces)
a
CH1 (RB 6 mm @ 0.20 m: 12 pieces)

a
SL1 (RB 9 mm: 4 pieces)

b
a
Steel Plate (thickness = 12 mm: 1
piece)
a
2
Mortar (0.32 m )
b
a
Ferrocement Cast-in-place Water Tank

(45 Cu. M.)
Designed by:
ACECOMS
ACECOMS, IFIC
School of Civil Engineering
Asian Institute of Technology (AIT)
Designed for:
United Nations High Commissioner for Refugees (UNHCR)

Content
Drawing Number
Title
CD45-01
Key Features
CD45-02
Plan, Elevation and Section
CD45-03
Foundation Details
CD45-04
Base Slab Details
CD45-05
Wall and Central Column Details
CD45-06
Roof Details
CD45-07
Reinforcing Steel Skeleton
CD45-08
Construction Tools and Steps
CD45-09
Material Specification and BOM
Key Features
Single Tank
Pipe dia. 50 -100
T1
Pipe dia. 50 -100

T2
T1
Pipe dia. 50 -100

T2
T1
T3
Plan - 3 Tanks
45 Cu. m
Diameter
5300
Height
2700
(2200+500)
Foundation
Compacted Sand/ Soil (thk. = 500)

Retained by Hollow Blocks/ Masonry Bricks
Base Slab
Reinforced Concrete (thk. = 120)
Wall
Ferrocement (thk. = 30)

Stiffened by Embedded Steel Channels
Roof

Stiffened by Embedded Trusses
Central
Column
GI Pipe (Diameter = 150) Filled with Mortar
Access
Opening
Diameter = 600 (in Roof)
Pipe Work
Intel, Outlet and Over Flow Pipes
T2
T3
Plan - 2 Tanks
Capacity
Finishing
T4
y
y
y
Inside Plastering Only

Outside Ordinary Paint
No Special Paint/Additives
Plan - 4 Tanks
Examples for Connecting Multiple Tanks
Note: - RB = Round Bar
For Same Water Head
Designed by
UNHCR

(45 Cu.m.)
ACECOMS
School of Civil Engineering (AIT)
For Different Water Head

(Overflow Type Connection)
Drawing Title:
- GI = Galvanized Iron
- All dimensions are in milimeter
- Foundation height depends
upon water head required
Drawing No:
Key Features
Scale: Not to Scale
Client: UNHCR
CD45-01
Date: March 2002
Hollow Blocks
or Masonary Brick
500
0
50
2200
600
Overflow Pipe
620
Overflow Pipe
00
53
Outlet Pipe
Elevation
Inlet Pipe
0
50
Ferrocement Roof
(thk.=30)
500
+ 2715
GI Pipe filled with Mortar
(dia.=150)
2200
Roof Plan
Ferrocement Wall
(thk.=30)
2100
Concrete Slab
(thk.=120)
Foundation
(thk = 500)
+ 620
620
+ 000
500
5300
500
Section 1-1
Designed by
UNHCR

(45 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD45-02
Date: March 2002
6300
Masonry Bricks
Ferrocement Wall
2
00
63
500
Masonry Brick Layout
Concrete Slab
500
Foundation Plan
(Level + 620)
30
Ferrocement Wall
+ 620
Concrete Base Slab
120
Lean Concrete
(Optional)
50
Compacted Sand
or Crushed Stone
200
Masonry Blocks
see Section 2-2
Compacted Soil
250
+ 000
Natural Ground
Section 2-2: Foundation Detail

Designed by
UNHCR

(45 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:
Foundation Details
Scale: Not to Scale
Client: UNHCR
CD45-03
Date: March 2002
Ferrocement Wall
Masonry Bricks
Hollow Blocks
0
50
00
53
0
50
200
200
Water Tank Plan
Base Slab Reinforcement Detail

RB 9 mm @ 200 #
(ST1 & SB1: 2 Layers)
RB 9 mm @ 100 (WV1 and WV2: see Detail 2)
0
30
RB 9 mm @ 200 (WH1)
Chicken mesh (WM1 & WM2)
RB 9 mm
400
120
see Sectoion 3-3
50
1000
300
+ 620
RB 9 mm
RB 9 mm @ 200# (ST1 & SB1)
RB 9 mm
2200
RB 9 mm @ 100 (SL1: see Detail 1)
RB 9 mm
30
WV1
SL1
Lean Concrete
Detail 1
WV2
Detail 2
Section 3-3: Slab Detail

Designed by
UNHCR

(45 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:
Base Slab Details

Scale: Not to Scale
Client: UNHCR
CD45-04
Date: March 2002
Truss
6
130
5
Steel Plate 300x300x12
500
4 x RB 9 Welded with Steel Plate
7
45
GI Pipe Filled with Mortar

(dia. = 150)
0
530
7
RB 6 @ 200 (CH1)
4 x RB 9 (CV1)
GI Pipe
Filled with Mortar
500
150
4 x RB 9 SL1
(see Detail 1 in dwg no: CD45-04)
Steel Channel
75 x 37.5
Ferrocement Wall
(thk. = 30)
Section 4-4: Water Tank Wall Section

30
Section 7-7: Central Column Detail
130
Construction Joint 2
see Section 7-7

RB 9 mm @ 100
(WV1 and WV2 alternated: see detail 2 in Dwg. CD45-04)
RB 9 mm @ 200 (WH1)
RB 9 mm @ 200 (WH1)
Chicken Mesh (WM1)
Chicken Mesh (WM1)
Chicken Mesh (WM2)
Chicken Mesh (WM2)
30
see Section 7-7
Steel Channel
73 x 37.5
Section 5-5
Section 6-6
Designed by
UNHCR

(45 Cu.m)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD45-05
Date: March 2002
9
11
Chicken Mesh (RM2)

30
RB 6 @ 200 (RC1)
10
RB 9 @ 200 (RD1 & RD2: Alternated)

10
Chicken Mesh (RM1)
Ferrocement Wall
RB 6 @ 200 (RC1)
Section 10-10: Roof Slab Detail

8
11
RB 9 @ 400 (RD1)
(L= 2600)
Chicken Mesh (RW2)
RB 9 @ 400 (RD2)
(L = 1500)
RB 6 @ 200 (RC1)
12
Truss Upper Cord

(RB 9: see Detail 3)
130
Welded with Steel Plate

Chicken Mesh (RW1)
2 layers of Chicken Mesh
(RM1 & RM2)
Diagonal Member (RB 6: see Detail 4)
12
Truss Lower Cord (RB 9: see Detail 3)
Section 9-9: Roof Framing Plan
Welded with Steel Channel
Section 11-11: Truss Detail
Steel Channel 75 x 37.5

Truss (see Section 11-11)
RB 9
Chicken Mesh (RM2)

30
RB 9 mm @ 200 (RD1 & RD2: Alternated)

100
Chicken Mesh (RM1)
200
2600
Detail 3: Truss Upper and Lower Cord Detail
RB 6 mm @ 200 (RC1)
30
100
10
Truss Upper Cord

(RB 9 mm: see Detail 3)

2600
Detail 4: Diagonal Member Detail
Welded to Upper and Lower Chord
Section 8-8: Truss Section

Designed by
UNHCR

(45 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:
Roof Details
Scale: Not to Scale
Client: UNHCR
CD45-06
Date: March 2002
Steel Plate 300 x 300 thk. 120

GI Pipe Filled with Mortar (dia. = 150)
4 x RB9 (CV1)
RB 6 @ 200 (CH1)
Chicken Mesh (RM1)
RB 9 @ 400 (RD2)
RB 9 @ 400 (RD1)
Chicken Mesh (RM2)
RB 6 @ 200 (RC1)
Truss (see dwg. CD45-06)
Steel Chanel 75 x 37.5
RB 9 @ 200 (WV1)
RB 9 @ 200 (WH1)
RB 9 @ 200 (WV2)
Chicken Mesh (WM1)
Chicken Mesh (WM2)
RB 9 @ 200 # ST1
RB 9 @ 200 # SB1
RB 9 @ 100 (SL1: see Detail 1)

4 RB 9
Note: Only Selected Typical Elements Shown

Designed by
UNHCR

(45 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD45-07
Date: March 2002
Construction Main Steps

Step 1: Selection of Site
Step 2: Site Clearance
Step 3: Preparation of Foundation
Step 4: Preparation of Lean Concrete Base
Step 5: Preparation of Base Slab Reinforcement
Step 6: Laying Base Slab Reinforcement
Step 7: Erecting L-bars Along the Wall-Base Junction
Step 8: Placing Vertical Dowel/ Plate/Bars for Central Column
Step 9: Casting the Base Slab
Step 10: Erection of Vertical Reinforcement and Stiffeners for Wall
Step 11: Keeping Openings for Construction and Pipe Works
Step 12: Fixing Wire (Chicken) Mesh (WM1 and WM2)
Step 13: Preparation and Fixing the Central Column
Step 14: Plastering the Wall
Step 15: Preparation of Roof Shallow Truss
Step 16: Fixing Roof Trusses (Roof Stiffeners)
Step 17: Placing Roof Reinforcements
Step 18: Fixing the Roof Mesh
Step 19: Providing Openings in the Roof
Step 20: Plastering Roof Trusses
Step 21: Temporary Formwork for Plastering of Roof Surface
Step 22: Plastering Roof Surface
Step 23: Plastering Temporary Openings
Ferrocement Construction Tools
Step 24: Finishing the Surface
[For Construction Procedure Details Refer to "How to Manual"]
Designed by
UNHCR

(45 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD45-08
Date: March 2002
Material Specification
Cement:
Use ordinary Portland cement Type I or II for tropical countries and Type II for cold
climates
Sand:
1.
2.
3.
4.
Use well graded sand. Sand that is too fine or too coarse is not suitable
Separate sand from stone using 6.4 mm (1/4 inch) mesh screen.
Desirable sand grading is as follow:
Sieve
Percent passing
3/8 in (9.5mm)
100
No. 4 (4.75mm)
95 to 100
No. 8 (2.36 mm)
80 to 100
No. 14 (1.18mm)
50 to 85
No. 30 (600um)
25 to 60
No. 100 (150um)
2 to 10
Water:
1. Water fit for drinking is suitable.

2. Salty water should never be used.
Wire Mesh:
1.
2.
3.
4.

Skeletal Steel :
1. Free from grease, oil detergents, organic matter, cracks of blow holes.
2. Bars are acceptable if no cracks appear after the following field test:
"Bend bar into U shape and then straighten it out. Bend it again in U shape in the
opposite direction and straighten it out."
3. Grade SR24: Yield strength = 2400-2600 ksc
Steel Channel:
1. Free from grease, oil detergents, organic matter, cracks of blow holes
2. Size 7.50 cm x 3.75 cm ( height x width)
3. Grade Fy = 2400-2600 ksc (34-36 ksi) and FU = 4,000-4,500 ksc (57-64 ksi)
Material Quantity Summary (45 cu. m.)

Items
Quantity
Coarse Sand
Hollow Blocks
Cement
Sand
Stone
Water
RB 6 mm
RB 9 mm
Steel Channel (7.50 cm x 3.75 cm)
Chicken Mesh
GI Pipe
Steel Plate
Unit
14
150
3267
4.26
5
1.67
164
1452
18
123
2.7
0.09
m2
pieces
kg
m2
m2
m2
m
m
m
m2
m
m2
Mix Proportions
Lean Concrete
Slab Concrete
Ferrocement Mortar = 1:2:0.4 (Cement: Sand: Water by weight)

Tie Wire:
Use annealed (soft) galvanized wires of 24 or 26 gauge. Cut pieces of wire from meshes
could also be used for tying.
Designed by
UNHCR

(45 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD45-09
Date: March 2002

(75 Cu. M.)
Designed by:
ACECOMS
ACECOMS, IFIC
Designed for:

Content
Drawing Number
Title
CD75-01
Key Features
CD75-02
CD75-03
Foundation Details
CD75-04
Base Slab Details
CD75-05
CD75-06
Roof Details
CD75-07
CD75-08
CD75-09
Key Features
Single Tank
Pipe dia. 50 -100
T1
Pipe dia. 50 -100

T2
T1
Pipe dia. 50 -100

T2
T1
T3
Plan - 3 Tanks
75 Cu. m
Diameter
6700
Height
2700
(2200+500)
Foundation

Base Slab
Wall

Roof

Central
Column
Access
Opening
Pipe Work
T2
T3
Plan - 2 Tanks
Capacity
Finishing
T4
y
y
y

Plan - 4 Tanks
For Same Water Head
Designed by
UNHCR

(75 Cu.m.)
ACECOMS

Drawing Title:
Drawing No:
Key Features
Scale: Not to Scale
Client: UNHCR
CD75-01
Date: March 2002
Hollow Blocks
or Masonary Brick
500
0
50
2200
600
Overflow Pipe
620
Overflow Pipe
00
67
Outlet Pipe
Elevation
Inlet Pipe
0
50
Ferrocement Roof
(thk.=30)
500
+ 2715
(dia.=150)
2200
Roof Plan
Ferrocement Wall
(thk.=30)
2100
Concrete Slab
(thk.=120)
Foundation
(thk = 500)
+ 620
620
+ 000
500
6700
500
Section 1-1
Designed by
UNHCR

(75 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD75-02
Date: March 2002
7700
Masonry Bricks
Ferrocement Wall
2
00
77
500
Concrete Slab
500
Foundation Plan
(Level + 620)
30
Ferrocement Wall
+ 620
Concrete Base Slab
120
Lean Concrete
(Optional)
50
Compacted Sand
or Crushed Stone
200
Masonry Blocks
see Section 2-2
Compacted Soil
250
+ 000
Natural Ground

Designed by
UNHCR

(75 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:
Foundation Details
Scale: Not to Scale
Client: UNHCR
CD75-03
Date: March 2002
Ferrocement Wall
Masonry Bricks
Hollow Blocks
0
50
00
67
0
50
200
200
Water Tank Plan

RB 9 mm @ 200 #
30
RB 9 mm @ 200 (WH1)
RB 9 mm
400
120
see Sectoion 3-3
50
1000
300
+ 620
RB 9 mm
RB 9 mm @ 200# (ST1 & SB1)
RB 9 mm
2200
RB 9 mm
30
WV1
SL1
Lean Concrete
Detail 1
WV2
Detail 2

Designed by
UNHCR

(75 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:
Base Slab Details

Scale: Not to Scale
Client: UNHCR
CD75-04
Date: March 2002
Truss
6
130
5
500
7
45

(dia. = 150)
0
670
7
RB 6 @ 200 (CH1)
4 x RB 9 (CV1)
GI Pipe
Filled with Mortar
500
150
4 x RB 9 SL1
Steel Channel
75 x 37.5
Ferrocement Wall
(thk. = 30)

30
130
see Section 7-7

RB 9 mm @ 100
RB 9 mm @ 200 (WH1)
RB 9 mm @ 200 (WH1)
Chicken Mesh (WM1)
Chicken Mesh (WM1)
Chicken Mesh (WM2)
Chicken Mesh (WM2)
30
see Section 7-7
Steel Channel
73 x 37.5
Section 5-5
Section 6-6
Designed by
UNHCR

(75 Cu.m)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD75-05
Date: March 2002
9
11
Chicken Mesh (RM2)

30
RB 6 @ 200 (RC1)
10

10
Chicken Mesh (RM1)
Ferrocement Wall
RB 6 @ 200 (RC1)

8
11
RB 9 @ 400 (RD1)
(L= 2600)
Chicken Mesh (RW2)
RB 9 @ 400 (RD2)
(L = 1500)
RB 6 @ 200 (RC1)
12
Truss Upper Cord

130

Chicken Mesh (RW1)
(RM1 & RM2)
12

RB 9
Chicken Mesh (RM2)

30

100
Chicken Mesh (RM1)
200
2600
RB 6 mm @ 200 (RC1)
30
100
10
0
Truss Upper Cord


2600

Designed by
UNHCR

(75 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:
Roof Details
Scale: Not to Scale
Client: UNHCR
CD75-06
Date: March 2002

4 x RB9 (CV1)
RB 6 @ 200 (CH1)
Chicken Mesh (RM1)
RB 9 @ 400 (RD2)
RB 9 @ 400 (RD1)
RB 6 @ 200 (RC1)
Chicken Mesh (RM2)
RB 9 @ 200 (WV1)
RB 9 @ 200 (WH1)
RB 9 @ 200 (WV2)
Chicken Mesh (WM1)
Chicken Mesh (WM2)
RB 9 @ 200 # ST1
RB 9 @ 200 # SB1

4 RB 9

Designed by
UNHCR

(75 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD75-07
Date: March 2002

Designed by
UNHCR

(75 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD75-08
Date: March 2002
Cement:
climates
Sand:
1.
2.
3.
4.
Sieve
Percent passing
3/8 in (9.5mm)
100
No. 4 (4.75mm)
95 to 100
No. 8 (2.36 mm)
80 to 100
No. 14 (1.18mm)
50 to 85
No. 30 (600um)
25 to 60
No. 100 (150um)
2 to 10
Water:

Wire Mesh:
1.
2.
3.
4.

Skeletal Steel :
Steel Channel:

Items
Quantity
Coarse Sand
Hollow Blocks
Cement
Sand
Stone
Water
RB 6 mm
RB 9 mm
Chicken Mesh
GI Pipe
Steel Plate
Unit
21
180
4553
6
7
2.4
242
1976
18
168
2.7
0.09
m2
pieces
kg
m2
m2
m2
m
m
m
m2
m
m2
Mix Proportions
Lean Concrete
Slab Concrete

Tie Wire:
Designed by
UNHCR

(75 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD75-09
Date: March 2002

(90 Cu. M.)
Designed by:
ACECOMS
ACECOMS, IFIC
Designed for:

Content
Drawing Number
Title
CD90-01
Key Features
CD90-02
CD90-03
Foundation Details
CD90-04
Base Slab Details
CD90-05
CD90-06
Roof Details
CD90-07
CD90-08
CD90-09
Key Features
Single Tank
Pipe dia. 50 -100
T1
Pipe dia. 50 -100

T2
T1
Pipe dia. 50 -100

T2
T1
T3
Plan - 3 Tanks
90 Cu. m
Diameter
7300
Height
2700
(2200+500)
Foundation

Base Slab
Wall

Roof

Central
Column
Access
Opening
Pipe Work
T2
T3
Plan - 2 Tanks
Capacity
Finishing
T4
y
y
y

Plan - 4 Tanks
For Same Water Head
Designed by
UNHCR

(90 Cu.m.)
ACECOMS

Drawing Title:
Drawing No:
Key Features
Scale: Not to Scale
Client: UNHCR
CD90-01
Date: March 2002
Hollow Blocks
or Masonary Brick
500
0
50
2200
600
Overflow Pipe
620
Overflow Pipe
00
73
Outlet Pipe
Elevation
Inlet Pipe
0
50
Ferrocement Roof
(thk.=30)
500
+ 2715
(dia.=150)
2200
Roof Plan
Ferrocement Wall
(thk.=30)
2100
Concrete Slab
(thk.=120)
Foundation
(thk = 500)
+ 620
620
+ 000
500
7300
500
Section 1-1
Designed by
UNHCR

(90 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD90-02
Date: March 2002
8300
Masonry Bricks
Ferrocement Wall
2
00
83
500
Concrete Slab
500
Foundation Plan
(Level + 620)
30
Ferrocement Wall
+ 620
Concrete Base Slab
120
Lean Concrete
(Optional)
50
Compacted Sand
or Crushed Stone
200
Masonry Blocks
see Section 2-2
Compacted Soil
250
+ 000
Natural Ground

Designed by
UNHCR

(90 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:
Foundation Details
Scale: Not to Scale
Client: UNHCR
CD90-03
Date: March 2002
Ferrocement Wall
Masonry Bricks
Hollow Blocks
0
50
00
73
0
50
200
200
Water Tank Plan

RB 9 mm @ 200 #
30
RB 9 mm @ 200 (WH1)
RB 9 mm
400
120
see Sectoion 3-3
50
1000
300
+ 620
RB 9 mm
RB 9 mm @ 200# (ST1 & SB1)
RB 9 mm
2200
RB 9 mm
30
WV1
SL1
Lean Concrete
Detail 1
WV2
Detail 2

Designed by
UNHCR

(90 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:
Base Slab Details

Scale: Not to Scale
Client: UNHCR
CD90-04
Date: March 2002
Truss
6
130
5
500
7
45

(dia. = 150)
0
730
7
RB 6 @ 200 (CH1)
4 x RB 9 (CV1)
GI Pipe
Filled with Mortar
500
150
4 x RB 9 SL1
Steel Channel
75 x 37.5
Ferrocement Wall
(thk. = 30)

30
130
see Section 7-7

RB 9 mm @ 100
RB 9 mm @ 200 (WH1)
RB 9 mm @ 200 (WH1)
Chicken Mesh (WM1)
Chicken Mesh (WM1)
Chicken Mesh (WM2)
Chicken Mesh (WM2)
30
see Section 7-7
Steel Channel
73 x 37.5
Section 5-5
Section 6-6
Designed by
UNHCR

(90 Cu.m)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD90-05
Date: March 2002
9
11
Chicken Mesh (RM2)

30
RB 6 @ 200 (RC1)
10

10
Chicken Mesh (RM1)
Ferrocement Wall
RB 6 @ 200 (RC1)

8
11
RB 9 @ 400 (RD1)
(L= 2600)
Chicken Mesh (RW2)
RB 9 @ 400 (RD2)
(L = 1500)
RB 6 @ 200 (RC1)
12
Truss Upper Cord

130

Chicken Mesh (RW1)
(RM1 & RM2)
12

RB 9
Chicken Mesh (RM2)

30

100
Chicken Mesh (RM1)
200
2600
RB 6 mm @ 200 (RC1)
30
100
10
0
Truss Upper Cord


2600

Designed by
UNHCR

(90 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:
Roof Details
Scale: Not to Scale
Client: UNHCR
CD90-06
Date: March 2002

4 x RB9 (CV1)
RB 6 @ 200 (CH1)
Chicken Mesh (RM1)
RB 9 @ 400 (RD2)
RB 9 @ 400 (RD1)
RB 6 @ 200 (RC1)
Chicken Mesh (RM2)
RB 9 @ 200 (WV1)
RB 9 @ 200 (WH1)
RB 9 @ 200 (WV2)
Chicken Mesh (WM1)
Chicken Mesh (WM2)
RB 9 @ 200 # ST1
RB 9 @ 200 # SB1

4 RB 9

Designed by
UNHCR

(90 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD90-07
Date: March 2002

Designed by
UNHCR

(90 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD90-08
Date: March 2002
Cement:
climates
Sand:
1.
2.
3.
4.
Sieve
Percent passing
3/8 in (9.5mm)
100
No. 4 (4.75mm)
95 to 100
No. 8 (2.36 mm)
80 to 100
No. 14 (1.18mm)
50 to 85
No. 30 (600um)
25 to 60
No. 100 (150um)
2 to 10
Water:

Wire Mesh:
1.
2.
3.
4.

Skeletal Steel :
Steel Channel:

Items
Quantity
Coarse Sand
Hollow Blocks
Cement
Sand
Stone
Water
RB 6 mm
RB 9 mm
Chicken Mesh
GI Pipe
Steel Plate
Unit
25
195
5078
7
7
2.62
279
2375
18
191
2.7
0.09
m2
pieces
kg
m2
m2
m2
m
m
m
m2
m
m2
Mix Proportions
Lean Concrete
Slab Concrete

Tie Wire:
Designed by
UNHCR

(90 Cu.m.)
ACECOMS
Drawing Title:
Drawing No:

Scale: Not to Scale
Client: UNHCR
CD90-09
Date: March 2002

Water Tank

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Large Ferro-Cement Water Tank

Design Parameters and Construction Details

Technical Support Section

Basis for Design and Underlying Concepts...........................................6

Prototype Construction and Test ...........................................................7

Construction Steps ..................................................................................9

-2Large Ferro-Cement Water Tank UNHCR, July 2006

Figure 9. Temporary Access ............................................................................11

-3Large Ferro-Cement Water Tank UNHCR, July 2006

Review the existing techniques used in ferro-cement construction and

Conduct a prototype test to ensure structural integrity, assess operational

-5Large Ferro-Cement Water Tank UNHCR, July 2006

Basis for Design and Underlying Concepts

Skill and technology requirements

Short and long term performance and

-6Large Ferro-Cement Water Tank UNHCR, July 2006

The cover to the first layer of reinforcement;

Thickness of wall and roof members;

Size of mesh opening;

Skeletal reinforcement depth, volume fraction of the reinforcement and

Fineness of matrix (mortar).

Prototype Construction and Test

-7Large Ferro-Cement Water Tank UNHCR, July 2006

Study its constructability aspects;

Verify the strength requirements; and

Study its water permeability (tightness) and initial stage performance.

Among several methods available for construction, the Skeletal/Armature method

Figure 1. Wall Cross-section on a Horizontal Plan in Skeletal/Armature Method of Construction

The strength requirements were verified as follows:

-8Large Ferro-Cement Water Tank UNHCR, July 2006

Figure 2. Tank after One Week of Filling

Figure 3. Tank after Two Weeks of Filling

-9Large Ferro-Cement Water Tank UNHCR, July 2006

Figure 4. Preparation of Foundation

Figure 5. Preparation of Lean Concrete Base

-10Large Ferro-Cement Water Tank UNHCR, July 2006

Figure 6. Placement of Rebar for Base Slab

Figure 7. Casting of Concrete Base Slab

Figure 8. Vertical Reinforcement and Wall

-11Large Ferro-Cement Water Tank UNHCR, July 2006

Figure 9. Temporary Access

Figure 10. Inlet/Outlet Opening

Figure 11. Overflow Opening

Figure 12. Fixed Wire Mesh

Figure 13. Fixing of Central Column

-12Large Ferro-Cement Water Tank UNHCR, July 2006

NOTE: Considering several factors, it is strongly recommended to finish the column to

openings so as to avoid leaks in the

Figure 14. Plastering of Wall

-13Large Ferro-Cement Water Tank UNHCR, July 2006

Figure 15. Fixing of Roof Trusses (Stiffeners)

Step 18: Providing Openings in the

Figure 18. Temporary Formwork for Roof

Figure 19. Plastering of Roof

Figure 20. Temporary Opening

Figure 21. Finished Ferro Cement Tank

3/8 in. (9.5 mm)

No. 100 (150m)

Must be easy to handle and flexible enough to be bent around corners.