Possibility of building a reinforced concrete/ferrocement hull in sections

Dong Hyeon Kim

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Back in WW2, there were barges made from joining together prefabricated ferrocement panels.

I wonder if anyone in the modern day tried reviving this technique. Seems to solve the issue with having to plaster a whole hull in one long session, though forming watertight and structurally sound joints wouldn't be the easiest thing to do.
 
But how would the different sections be joined together? Bolted, using plates welded to the armature under the mesh?

I think it is a no-brainer nowadays - when you factor in the additional labour cost to build a ferro barge, compared to building a simple steel barge, I am sure that the steel barge will come out significantly cheaper.
 
But how would the different sections be joined together? Bolted, using plates welded to the armature under the mesh?

I think it is a no-brainer nowadays - when you factor in the additional labour cost to build a ferro barge, compared to building a simple steel barge, I am sure that the steel barge will come out significantly cheaper.

No idea, perhaps someone more knowledgeable in ferrocement construction ought to have ideas. It seems like there's only a few photos of this construction method.
 

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Back in WW2, there were barges made from joining together prefabricated ferrocement panels.

I wonder if anyone in the modern day tried reviving this technique. Seems to solve the issue with having to plaster a whole hull in one long session, though forming watertight and structurally sound joints wouldn't be the easiest thing to do.
The Ritchie Unit System dates from WW1, altough it was extensively used in WW2. This is his book, maybe you can also find it in a library (ask for an interlibrary loan if necessary). A New Way of Building Concrete Ships. The Ritchie Unit System. A Short Account Illustrating the Old Method and the New of Building Concrete Ships. by Ritchie & Black.: Very Good | ROBIN SUMMERS BOOKS LTD https://www.abebooks.com/first-edition/New-Way-Building-Concrete-Ships-Ritchie/31956055903/bd

To my knowledge precast elements are sometimes used today in concrete dock constructions that employ pretensioning/prestressing.
The big question is if assembling precast components is actually more economical then formless spraying of shells as pioneered by Ulrich Finsterwalder for Dyckerhoff & Widmann.

But how would the different sections be joined together? Bolted, using plates welded to the armature under the mesh?
A little bit more complicated then that. The individual panels are joined via a pin and wedge connection to form the hull shell. The panels are about 50mm thick and span one or two frame bays, depending on the size of the ship. Then a complete system of longitudinal and diagonal stringers is cast in place on the inside, forming something resembling a modern isogrid. The plates have protruding anchors to tie the rebar for the stringers to the plates. Ritchie also invented a steel spring clip to be used instead of tie wire for rebar in order to reduce assembly time.
This picture shows the construction relatively clearly:
Ritchie system.jpg
 
Whoa, thanks!

I knew of the existence of the book, but I live in Asia. I don't think there is a single library in the country that has that sort of book.

I assume there was a minimum size for his method of construction, maybe the low dozens of tons at the very least? Had that been the case then I can understand why similar methods haven't been utilized by hobbyists.
 
Getting insurance on a ferro cement boat today is extremely difficult, and in some countries impossible. A new build would most likely require supervised building from a known class surveyor, to get insurance. When you can not obtain even third party insurance, you can not even stay in marinas.
Pity really, I have watched 3 builds on plastering day, have met many well travelled boats, and even owned a ferro boat myself. If they have been constructed right from the start, they are very good.
 
I assume there was a minimum size for his method of construction, maybe the low dozens of tons at the very least? Had that been the case then I can understand why similar methods haven't been utilized by hobbyists.
It's not neceserally about the size but about the equipment. Amateurs don't usually own vibrating tables and cranes to be able to make even flat panels. This was a method geared primarily towards mass production. It is however possible to adapt it to amateur construction using a minimum of special panels, with bolting and epoxy for assembly, even for relatively small boats, cementing the panels by hand. In fact that's what a team of students (TU Dresden 2011) did once for the open class of a concrete canoe race, making an open boat, 11.8mx1.8mx0.65m, 2.8t, from 0.525m long identical segments (full transverse pieces) plus stem and stern sections. The segments were done in a closed mold using self compacting concrete and came out at 135kg. There were two segments with bulkheads at the end, each 230kg, serving as anchor points for the post stressing rods that hold everything together, plus the stem and stern pieces, done with textile reinforcement instead of steel. The whole boat was done using two molds, one for the standard sections and one for the stem section, wich was then modified to build the stern (they inserted a bulkhead to form the transom).
 
There are modern materials to seal the sections. If they are fabricated with flanges, it is possible to bolt them together. Adhesive caulks have come a long way from the 1940s.
 
There was/is (?) a kayak built of concrete at a university in Krakow.

It's nothing special. But the fact that I bought glue to repair external stairs is already something.

My old man, taught by experience, left some excess glue after the repair, thinking that it would be sanded off with shoes anyway.

No way. After 1.5 exposure to changing conditions it looks like it was done yesterday.

It's easy to think that a boat made of that glue reinforced with facade mesh would be lighter than many made of glass mat.
 
It's easy to think that a boat made of that glue reinforced with facade mesh would be lighter than many made of glass mat.
Not at all. The material properties are completely different, including density. Easy to think does not mean it has any connection to reality.
 
Not at all. The material properties are completely different, including density. Easy to think does not mean it has any connection to reality.
We don't know until we try.
There are different reinforcing meshes... and different adhesives.
The number of layers and fiber orientation can change a lot.
 
We don't know until we try.
There are different reinforcing meshes... and different adhesives.
The number of layers and fiber orientation can change a lot.
We know because we have put the time and effort into learning. On the other hand, you have the square wheel syndrome. Every expert is a fool because your square wheel is different, therefore better. Instead of being arrogant and making wild claims, show an example that proves me wrong. That would be interesting and I would welcome the lesson.
 
A whole bunch of Ferro 30ft Colin Archer types were built that required MORE ballast than the wooden hulls built to the same lines. Just one example.
 
A whole bunch of Ferro 30ft Colin Archer types were built that required MORE ballast than the wooden hulls built to the same lines. Just one example.
Collin Archer boats are very heavy, so not typical at all for modern boats. Maybe compared them to a Frers or Ron Holland to be more in line with current expectations.
 
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