This book is included in the Self Reliance Transportation section.
Introduction This book is derived from the papers and discussions of the first FAO Seminar on the Design and Construction of Ferro-Cement Fishing Vessels held in Wellington, New Zealand, from 9 to 13 October 1972. When FAO began investigating the possibilities of ferro-cement as a boatbuilding material in 1967, the relatively high component of unskilled labour plus the widespread availability of most of the necessary construction materials suggested that this might be of considerable value in promoting the construction of simple, comparatively inexpensive fishing boats in the developing world. The opinions expressed and the reports quoted in the discussions in Part IV of this book confirm this assumption and suggest that the use of ferro-cement in construction may also be extended into many other fields of interest to developing nations. The building of small fishing vessels has traditionally been a field in which very little engineering data have been available concerning the forces acting on hulls. In contrast to the detailed studies of the stresses to which large ship hulls are subjected, there was little information for small vessels. Design of small boats relied heavily on past experience and tables of scantlings for traditional construction materials were evolved through trial and error. This situation has changed in recent years. By 1972 engineering studies of material properties had provided more detailed information for the designer, new construction techniques had been evolved for different labour situations, and sufficient numbers of boats had been built, and data collected on them, for a pattern of service experience to emerge providing a further fund of information for designers and builders. One of the most important factors contributing to the development and application of any new material is the rapid and wide dissemination of information about current work being done, both in the experimental determination of engineering properties and in the field of practical applications. FAO, therefore, considered it timely to arrange for an exchange of information between people working world-wide in this field. The Seminar, on which this book is based, was the result and it is hoped that the information from the Seminar, as presented here, will assist in the promotion of this most interesting material, especially in its application in the developing world. Thanks are due to the authors of papers and to the speakers who contributed to the discussions. Special reference should be made to the work of the late Mr W Morley Sutherland, a pioneer in ferro-cement boat construction, who contributed two papers to the Seminar. Failing health prevented him from attending the Seminar, to the regret of all participants, and his untimely death is a loss to the field of ferro-cement. We at FAO express our gratitude to the Government of New Zealand, not only for their invitation to act as hosts for the Seminar but also for their highly efficient organizational support, which contributed so much to the success of the Seminar. It was particularly appropriate for the meeting to be held in New Zealand because that country is in the forefront of development in the use of ferro-cement and participants were able to see, on the spot, the varied range of construction now being undertaken by New Zealand boatbuilders, both amateur and commercial. F E Popper Assistant Director-General (Fisheries) Food and Agriculture Organization of the United Nations Rome, September 1973 Table of Contents Part I MATERIAL PROPERTIES The Intensity and Distribution of Cracking in Ferro-Cement Panels Subject to Flexure, T E Buchner Limits of Investigation Test Specimen and Apparatus Test Procedure and Results Discussion of Test Results Conclusions Dynamic Point Loading of Ferro-Cement, Glassfibre-reinforced Polyester and Plywood, H-P Pedersen Test Samples and Testing Equipment Described Presentation of Test Results Comparison of Hulls of Glassfibre Reinforced Polyester (GRP) and Ferro-Cement Test Results in Relation to Strength of Panels in a Boat Structure Conclusions Concrete Technology in the Quality Control of Ferro-Cement Vessels, T G Kowalski and B R Walkus Concrete Technology Test Samples Aggregates Cements Additives and Workability Curing Concrete Design Parameters Construction Stages Impact Conclusion Strength and Cracking of Ferro-Cement, S P Shah and M G Srinivasan Uniaxial Tension Uniaxial Compression Flexure Shear Impact Creep Fatigue Design Recommendations Mechanical Properties of Ferro-Cement, S-L Lee, M Raisinghani and R P Pama Properties of Ferro-Cement Bending of Ferro-Cement Experimental Investigation Conclusions Practical Ferro-Cement Design, Reinforced and Post-Tensioned, P E Ellen Types of Reinforcement Concretes Strength Design Bending Flexure Crack Control Tension Bond Values Spacing of Mesh Layers Sections in Pure Tension Sections Subject to Bending Moments and Tensile Forces Impact and Shear Values of Highly Reinforced Slabs Basic Hull Design Post-Tension Design Additives to Concrete Comments on Design Conclusion Appendix 1 Analysis of the Properties of Ferro-Cement Type Reinforcement Definition of Ferro-Cement G W Bigg Scope Use of Engineering Terminology Nature of Concrete Mortars Definition of Ferro-Cement Mortar Ferro-Cement as a Composite Material Reinforcement Configuration Specification Definition of Ferro-Cement Conclusions Ferro-Cement The Design of its Properties for Marine Usage, H M Moor Designing for Manufacture Designing for Strength Designing for Durability Future Developments Conclusions Discussion on the Material Properties of Ferro-Cement Testing of Ferro-Cement as a Means of Analysing Behaviour Mortar Cover, Cracking and Crack Width Cement Quality and its Testing Cement in Reaction with Galvanized Mesh and Black-Steel Reinforcing Bars Sand and Sand Grading Additives used in the Mortar Mix Reinforcement Definition of Ferro-Cement Part II SCANTLINGS AND REGULATIONS Ferro-Cement Boat Hulls Analysed by the Finite Element Method, J C Scrivener and A J Carr Data and Analysis Ferro-Cement Properties Computed Hull Stresses Conclusions Estimation of Design Loads, G L Bowen Estimation Methods Discussed Full-Scale Testing Conclusions Recommendations Discussion of Scantlings Design and Various Official Regulations Analysis of Hulls by the Finite Element Method Hydrodynamic Loading of Ferro-Cement Hulls Scantlings and Construction Rules of Marine Boards and Classification Societies Publications of Classification Societies American Bureau of Shipping, Lloyds Register of Shipping, Marine Board of Queensland, N.Z. Marine Department Part III CONSTRUCTION METHODS AND COSTS Construction, Maintenance and Repair of a 26-Metre Ferro-Cement Stern Trawler, P A Leonard Design Research and Testing Construction Curing Construction Cost Trials Classification Maintenance and Repair Conclusion Ferro-Cement Vessels on the Pacific Coast of North America, P Noble and W Cleaver Types of Vessels Construction Methods and Techniques Mortar Preparation and Application Maintenance and Service Experience Construction Costs Future Construction of a 32-Metre Ferro-Cement Barge and Other Applications of Ferro-Cement, D Nontanakorn Properties of Ferro-Cement Ferro-Cement Barge Construction Other Uses of Ferro-Cement Conclusions Ferro-Cement Boats Commercial Production Methods in New Zealand, W M Sutherland Frame Construction Sandwich Construction Mass Production Techniques Conclusions Use of a Cavity Mould for Constructing 15-Metre Ferro-Cement Fishing Boats, R W Behnke and E C Doleman Design Mould Construction Hull Construction Cost Lessons Learned Mathematical Model Evaluation Conclusions The Use of Kit-Sets for Amateur Construction, G Carkeek Plans Lofting Types of Frames Permanent Jigs Quality Control Marketing Transportation Costs Explosive Moulding of Ferro-Cement Armatures, R C Pickett and J C Black History Scope of Experiments Construction of Mould Design Limitations Mesh Placement Explosives Decks and Bulkheads Plastering the Hull Conclusion A Construction Technique Using Pre-Cast Spans, H E Hermanson Why Pre-Cast Spans? Building the Mould Fabricating the Span Cementing the Frames Erecting the Armature Cementing the Hull Engine Beds Other Details Conclusions A Protective Coating System for Ferro-Cement Boats, A R Pavey Ferro-Cement as a Coating Substrate Need for Protecting Ferro-Cement Hulls Requirements of a Successful Protective Coating Types of Suitable Coatings Choice of Coating System Recommended Sequence for Coating Protecting the Hull Interior Performance History Conclusions Protection and Finishing of Ferro-Cement Hulls, P B Hunt Sealing of the Hull Filling and Fairing Fitting Out Exterior Finishing of Work Boats Exterior Finishing of Pleasure Craft Repair Conclusions Ferro-Cement Fishing Vessels Designed by FAO, J F Fyson, O Gulbrandsen and A F Haug Presentation of Boat Designs Design Considerations Construction Methods Materials Experience Weight and Cost Estimates for Small Fishing Vessels, O Gulbrandsen Weight Estimate Methods Cost Estimate Appendix 1 Subdivision for Weight and Cost Calculation Appendix 2 Example : Estimate of Structural Hull Cost of a 12.6-m Trawler Based on Costs in East Africa (U.S.J) The Cost of Ferro-Cement Boat Construction in India, M A K Tayab Ferro-Cement Project Initiated Details of Construction Cementing of the Boat An Analysis of Cost Factors Comparative Cost of Boats Built of Various Materials Response from the Fishermen Discussion Covering Construction Methods and Costs Constructing the Armature Construction Methods Using Moulds Mixing and Applying the Mortar Curing Voids and Grouting Painting and Coating Systems Fitting Out of Ferro-Cement Hulls Costs of Construction Part IV SERVICE EXPERIENCE Survey of Ferro-Cement Fishing Boats Built in New Zealand, D J Eyres Construction Requirements Materials Service Experience Conclusions Experience of 300 Commercially Built Craft in More Than 20 Countries, T M Hagenbach Customer Reaction Survey of Mishaps and Accidents Areas for Further Research What of the Future? Ferro-Cement Boats Service - Experience in New Zealand, W M Sutherland Weight Factors Mortar Application and Penetration Steel Corrosion Electrolysis Skin Fittings Oil Paint Structural Strength - Cracking Punching Fire Resistance Permeability Conclusions Discussion on Aspects of Service Experience Accident Damage and its Repair Corrosion in Ferro-Cement Boats Diesel Oil in Contact with Ferro-Cement Combination of Materials to Improve Certain Characteristics of Ferro-Cement Fire Risk and Insurance Standards for Reporting Service Experience Service Report on Ferro-Cement Fishing Vessel Potential of Ferro-Cement in Developing Countries End of Preview.
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