Build A Ferrocement Tank: DIY Guide For Durable Water Storage

by Felix Dubois 62 views

Are you looking for a cost-effective and long-lasting solution for water storage? Ferrocement tanks are the answer! These tanks are surprisingly durable, relatively inexpensive to build, and can be constructed with basic DIY skills. In this comprehensive guide, we'll walk you through the process of building your own ferrocement tank, providing tips and tricks along the way. Whether you're a seasoned DIY enthusiast or just starting out, this project is achievable with the right guidance. So, let's dive in and discover how you can create a reliable water storage system for your home or garden.

Why Choose a Ferrocement Tank?

Before we get into the nitty-gritty of construction, let's explore why ferrocement tanks are such a popular choice for water storage. There are several compelling reasons to consider this method:

  • Durability: Ferrocement tanks are incredibly strong and resistant to cracking and leaks. The combination of cement mortar and layers of wire mesh creates a robust structure that can withstand significant pressure and environmental stresses. This makes them a long-lasting solution for water storage, providing years of reliable service.
  • Cost-Effectiveness: Compared to traditional water tanks made of concrete or steel, ferrocement tanks are significantly more affordable. The materials used in construction – cement, sand, and wire mesh – are readily available and relatively inexpensive. This makes ferrocement tanks an excellent option for those on a budget who don't want to compromise on quality.
  • Ease of Construction: With basic DIY skills and the right instructions, anyone can build a ferrocement tank. The construction process is straightforward and doesn't require specialized equipment or expertise. This makes it an ideal project for homeowners, gardeners, and anyone interested in sustainable living.
  • Versatility: Ferrocement tanks can be built in various shapes and sizes to suit your specific needs. Whether you need a small tank for garden irrigation or a large tank for household water storage, ferrocement construction can be adapted to your requirements. This versatility makes them a practical solution for a wide range of applications.
  • Water Conservation: By building your own ferrocement tank, you can collect and store rainwater, reducing your reliance on municipal water supplies. This not only saves you money on your water bill but also helps conserve a valuable natural resource. Rainwater harvesting is an environmentally friendly practice that contributes to a more sustainable lifestyle.

Planning Your Ferrocement Tank

Before you start cutting and mixing, careful planning is essential for a successful ferrocement tank build. Here's what you need to consider:

Determine the Tank Size

The first step is to calculate the amount of water you need to store. This will depend on your intended use for the water, such as garden irrigation, household use, or emergency storage. Consider your water consumption patterns and any seasonal variations in demand. It's always better to err on the side of caution and build a tank that's slightly larger than your estimated needs.

To determine the tank size, you'll need to estimate your daily water usage and multiply it by the number of days of storage you want. For example, if you use 100 gallons of water per day and want to store enough water for 7 days, you'll need a tank with a capacity of at least 700 gallons.

Choose the Tank Shape

Ferrocement tanks can be built in various shapes, including cylindrical, rectangular, and spherical. Cylindrical tanks are the most common due to their structural efficiency and ease of construction. They distribute pressure evenly, making them less prone to cracking. Rectangular tanks are easier to integrate into existing structures but may require additional reinforcement. Spherical tanks are aesthetically pleasing but more complex to build.

The shape of your tank will also influence the size and type of formwork you need. Cylindrical tanks can be built using simple circular forms, while rectangular tanks require more elaborate formwork to maintain their shape during construction.

Select the Tank Location

Choosing the right location for your ferrocement tank is crucial for its longevity and ease of use. Consider the following factors:

  • Accessibility: The tank should be easily accessible for filling, cleaning, and maintenance. Ensure there's enough space around the tank to work comfortably.
  • Foundation: The ground should be stable and level to support the weight of the filled tank. If the soil is unstable, you may need to build a concrete foundation.
  • Proximity to Water Source: Ideally, the tank should be located close to your water source, such as a rainwater harvesting system or a well. This will minimize the distance water needs to be pumped or transported.
  • Sunlight Exposure: Avoid placing the tank in direct sunlight, as this can promote algae growth and reduce water quality. If necessary, provide shade with a roof or vegetation.

Gather Your Materials and Tools

Before you start building, make sure you have all the necessary materials and tools. Here's a comprehensive list:

  • Cement: Use Portland cement for its strength and durability. The amount of cement you need will depend on the size of your tank.
  • Sand: Use clean, sharp sand for the mortar mix. Avoid using sand with high clay content, as this can weaken the ferrocement.
  • Water: Use clean, potable water for mixing the mortar.
  • Wire Mesh: Galvanized chicken wire or hexagonal wire mesh is ideal for ferrocement construction. You'll need several layers of mesh to provide adequate reinforcement.
  • Rebar (Reinforcing Bars): Rebar is used to create a strong framework for the tank. The diameter and spacing of the rebar will depend on the tank size and design.
  • Binding Wire: Use binding wire to tie the wire mesh and rebar together.
  • Formwork Materials: You'll need materials to create a form for the tank. This could include plywood, metal sheets, or even an inflatable bladder.
  • Wire Cutters: Use wire cutters to cut the wire mesh to size.
  • Pliers: Pliers are useful for bending and twisting the binding wire.
  • Shovels and Buckets: You'll need shovels for mixing the mortar and buckets for transporting it.
  • Trowels: Trowels are used to apply the mortar to the wire mesh.
  • Gloves: Wear gloves to protect your hands from the cement.
  • Safety Glasses: Wear safety glasses to protect your eyes from dust and debris.
  • Measuring Tape: A measuring tape is essential for accurate measurements.
  • Level: Use a level to ensure the tank is built on a level surface.

Step-by-Step Guide to Building a Ferrocement Tank

Now that you've planned your tank and gathered your materials, it's time to start building. Here's a step-by-step guide to the construction process:

1. Prepare the Foundation

A solid foundation is crucial for the stability and longevity of your ferrocement tank. If the ground is uneven or unstable, you'll need to build a concrete foundation. Here's how:

  • Excavate the Site: Dig a shallow pit that's slightly larger than the base of your tank.
  • Compact the Soil: Use a tamper to compact the soil at the bottom of the pit.
  • Pour a Concrete Slab: Mix concrete according to the manufacturer's instructions and pour it into the pit. Use a level to ensure the slab is flat and level.
  • Cure the Concrete: Allow the concrete to cure for at least 7 days before proceeding with the tank construction.

2. Build the Framework

The framework provides the basic shape and structure of the tank. Here's how to build it:

  • Cut and Bend the Rebar: Cut the rebar to the required lengths and bend it into the desired shape. For a cylindrical tank, you'll need to create circular hoops and vertical bars.
  • Assemble the Rebar Cage: Tie the rebar hoops and vertical bars together using binding wire to create a cage-like structure. The spacing between the rebar will depend on the tank size and design.
  • Position the Rebar Cage: Place the rebar cage on the foundation, ensuring it's centered and level.

3. Apply the Wire Mesh

The wire mesh provides the reinforcement for the ferrocement. Here's how to apply it:

  • Cut the Wire Mesh: Cut the wire mesh into sheets that are large enough to wrap around the rebar cage. Use wire cutters for this task.
  • Wrap the Rebar Cage: Wrap the wire mesh around the rebar cage, overlapping the edges by several inches. Secure the mesh to the rebar using binding wire.
  • Apply Multiple Layers: Apply several layers of wire mesh, typically 4-6 layers, to provide adequate reinforcement. Tie each layer securely to the rebar and the previous layer of mesh.

4. Prepare and Apply the Mortar

The mortar is the heart of the ferrocement. It binds the wire mesh and rebar together, creating a strong, watertight structure. Here's how to prepare and apply the mortar:

  • Mix the Mortar: Mix the cement, sand, and water in the correct proportions. A typical mix ratio is 1 part cement to 2 parts sand. Add water gradually until you achieve a smooth, workable consistency.
  • Apply the First Layer: Apply a thin layer of mortar to the wire mesh, working it into the mesh openings. Use a trowel to smooth the surface.
  • Apply Subsequent Layers: Apply additional layers of mortar, allowing each layer to dry slightly before applying the next. The total thickness of the mortar should be at least 1 inch.
  • Cure the Mortar: Keep the mortar moist for at least 7 days to allow it to cure properly. You can do this by covering the tank with plastic sheeting or spraying it with water regularly.

5. Finishing Touches

Once the mortar has cured, you can add the finishing touches to your ferrocement tank:

  • Apply a Waterproof Coating: Apply a waterproof coating to the inside of the tank to prevent leaks. This could be a cement-based sealant or a flexible membrane.
  • Install an Inlet and Outlet: Install an inlet pipe for filling the tank and an outlet pipe for drawing water. Use PVC pipes and fittings for this purpose.
  • Add an Overflow Pipe: Install an overflow pipe to prevent the tank from overfilling.
  • Build a Lid: Build a lid for the tank to prevent debris and sunlight from entering. This could be made of ferrocement, wood, or metal.

Tips for Success

Building a ferrocement tank is a rewarding project, but it's important to do it right. Here are some tips to help you succeed:

  • Follow the Instructions Carefully: This guide provides a general overview of the construction process. For detailed instructions and specific design considerations, consult a ferrocement construction manual or seek advice from an experienced builder.
  • Use Quality Materials: Using high-quality materials will ensure the durability and longevity of your tank. Don't skimp on cement, sand, or wire mesh.
  • Mix the Mortar Properly: The mortar mix is crucial for the strength of the ferrocement. Follow the recommended mix ratio and ensure the mortar is well-mixed and workable.
  • Apply the Mortar Evenly: Applying the mortar evenly will ensure the tank is structurally sound. Use a trowel to smooth the surface and work the mortar into the mesh openings.
  • Cure the Mortar Properly: Curing the mortar is essential for its strength and durability. Keep the mortar moist for at least 7 days to allow it to cure properly.
  • Work as a Team: Building a ferrocement tank is a labor-intensive project. Working with a team of friends or family members will make the job easier and more enjoyable.

FAQs About Ferrocement Tanks

Here are some frequently asked questions about ferrocement tanks:

How long will a ferrocement tank last?

A properly built ferrocement tank can last for 50 years or more with minimal maintenance.

Are ferrocement tanks safe for drinking water?

Yes, ferrocement tanks are safe for storing drinking water as long as they are properly constructed and lined with a food-grade sealant.

How much does it cost to build a ferrocement tank?

The cost of building a ferrocement tank depends on the size of the tank and the cost of materials in your area. However, ferrocement tanks are generally more affordable than traditional concrete or steel tanks.

Can I build a ferrocement tank on my own?

Yes, you can build a ferrocement tank on your own with basic DIY skills and the right instructions. However, it's helpful to have some assistance, especially for larger tanks.

How do I maintain a ferrocement tank?

Ferrocement tanks require minimal maintenance. Periodically inspect the tank for cracks or leaks and repair them as needed. Clean the tank every few years to remove sediment and debris.

Conclusion

Building a ferrocement tank is a rewarding project that can provide you with a durable, affordable, and sustainable solution for water storage. By following the steps outlined in this guide and taking your time, you can build a tank that will serve your needs for many years to come. So, gather your materials, grab your tools, and get ready to create your own ferrocement masterpiece!

This comprehensive guide should provide you with all the information you need to get started on your ferrocement tank project. Remember to prioritize safety, follow the instructions carefully, and don't hesitate to seek help if you need it. Happy building, guys!