Build A Ferrocement Tank A DIY Guide To Durable Water Storage

by Axel Sørensen 62 views

Hey guys! Are you looking for a durable, inexpensive, and easy way to store water? Then ferrocement tanks might just be the perfect DIY project for you! In this article, we'll dive into how you can build your own ferrocement tank, so you can have a reliable water storage solution right in your backyard. Let's get started!

Why Choose Ferrocement Tanks?

Before we jump into the nitty-gritty of building a ferrocement tank, let's talk about why they're such a great option. Ferrocement is a composite material made from cement mortar reinforced with layers of wire mesh. This combination results in a structure that's incredibly strong and resistant to cracking, making it ideal for water storage. But that's not all – here are some other perks:

  • Durability: Ferrocement tanks can last for decades with proper construction and maintenance. They're resistant to fire, pests, and even earthquakes!
  • Cost-Effective: The materials needed for ferrocement tanks are relatively inexpensive and readily available, making them a budget-friendly option.
  • Easy to Build: With basic DIY skills and the right guidance, you can construct a ferrocement tank yourself. It's a rewarding project that saves you money and gives you a reliable water storage solution.
  • Versatile: Ferrocement tanks can be built in various shapes and sizes to fit your specific needs and space.
  • Water Conservation: By having your own water storage, you can collect rainwater or store water from other sources, helping you conserve water and reduce your reliance on municipal supplies.

So, if you're looking for a durable, cost-effective, and DIY-friendly way to store water, ferrocement tanks are definitely worth considering. Now, let's get into the construction process!

Planning Your Ferrocement Tank

Before you start cutting and mixing, careful planning is key to a successful ferrocement tank project. Think of it as laying the groundwork for a solid, long-lasting structure. Here’s what you need to consider:

1. Determining the Tank Size

The size of your ferrocement tank will depend on your water storage needs. Consider factors like your household's water consumption, local rainfall patterns (if you plan to collect rainwater), and any other water sources you might have. Estimate how much water you typically use in a week or month, and factor in any potential droughts or dry spells. It's always better to err on the side of having more storage capacity than you think you'll need. Imagine running out of water in the middle of a heatwave – not a fun situation, right? So, do your homework and calculate your water needs accurately.

2. Choosing the Tank Location

The location of your ferrocement tank is crucial for its functionality and longevity. Look for a flat, stable area that can support the weight of the filled tank. Remember, water is heavy! You'll also want to ensure the location is accessible for construction and maintenance. Think about how you'll get materials to the site and how you'll access the tank for cleaning or repairs. If you're planning to collect rainwater, position the tank near your downspouts for easy connection. Also, consider the aesthetics – you don't want your tank to be an eyesore. Choose a spot that's discreet but still practical. A well-chosen location will make your tank easier to use and maintain for years to come.

3. Selecting the Tank Shape

Ferrocement tanks can be built in various shapes, each with its own advantages. Cylindrical tanks are common due to their structural efficiency and ease of construction. Rectangular tanks can be a good option for fitting into tight spaces. Spherical tanks offer excellent strength but are more challenging to build. The shape you choose will depend on your space constraints, aesthetic preferences, and construction skills. Cylindrical tanks are often the go-to for DIYers because they're relatively simple to form and reinforce. But if you have a specific spot in mind, a rectangular tank might be a better fit. Consider all the angles before making your decision!

4. Gathering Materials and Tools

Once you've determined the size, location, and shape of your tank, it's time to gather your materials and tools. This is like prepping your kitchen before a big cooking project – you want everything at your fingertips. Here's a basic list of what you'll need:

  • Cement: The binding agent for your mortar. Use a high-quality Portland cement for best results.
  • Sand: Provides bulk and strength to the mortar. Use clean, sharp sand that's free of organic matter.
  • Water: Essential for mixing the mortar. Use clean, potable water.
  • Wire Mesh: The reinforcing material for your ferrocement. Chicken wire or hexagonal wire mesh is commonly used.
  • Rebar: Steel reinforcing bars for added strength, especially for larger tanks.
  • Binding Wire: Used to tie the wire mesh and rebar together.
  • Formwork Material: Plywood or other materials to create the shape of your tank (for cylindrical or rectangular tanks).
  • Wire Cutters: For cutting the wire mesh.
  • Pliers: For twisting and securing the binding wire.
  • Shovels: For mixing the mortar.
  • Buckets: For carrying water and mortar.
  • Trowels: For applying the mortar.
  • Gloves: To protect your hands.
  • Safety Glasses: To protect your eyes.
  • Measuring Tape: For accurate measurements.
  • Level: To ensure your tank is level.

Make a detailed list of all the materials and tools you need before you start. This will save you time and frustration in the long run. It's like having a recipe and making sure you have all the ingredients before you start cooking – nobody wants to run to the store mid-project!

Step-by-Step Guide to Building Your Ferrocement Tank

Alright, guys, now for the fun part – actually building your ferrocement tank! This is where your planning and preparation pay off. Follow these steps carefully, and you'll be well on your way to having your own water storage solution.

Step 1: Preparing the Foundation

The foundation is the most important part, acting as the backbone for your ferrocement tank. A solid foundation ensures your tank remains stable and prevents cracking or settling over time. Start by clearing the area of any vegetation, rocks, or debris. This creates a clean, level surface to work on. Next, compact the soil thoroughly. You can use a hand tamper or a mechanical compactor for this step. A well-compacted base prevents the tank from sinking or shifting. If the soil is particularly soft or unstable, you might need to add a layer of gravel for extra support. This is like building a strong base for a skyscraper – you want it to be able to handle the weight. Once the soil is compacted, pour a concrete slab as the foundation. The thickness of the slab will depend on the size of your tank, but a minimum of 4 inches is generally recommended. Reinforce the concrete slab with rebar to add extra strength. This is like adding steel beams to a building – it provides crucial support. Use a level to ensure the slab is perfectly level. An uneven foundation can lead to stress points in the tank walls and potentially cause leaks. Let the concrete cure for at least 7 days before proceeding to the next step. Curing allows the concrete to reach its full strength. Think of the foundation as the anchor for your tank – a well-prepared foundation is essential for a long-lasting structure.

Step 2: Creating the Tank Framework

Next up, you need to create the framework that will give your ferrocement tank its shape and structural integrity. This is where the wire mesh and rebar come into play. Start by bending the rebar into the desired shape for your tank walls. For a cylindrical tank, you'll need to bend the rebar into hoops. For a rectangular tank, you'll need to create a frame using rebar. Secure the rebar framework to the foundation using binding wire. This creates a sturdy skeleton for the tank walls. Next, wrap layers of wire mesh (chicken wire or hexagonal wire mesh) around the rebar framework. Overlap the edges of the wire mesh to ensure complete coverage. Secure the wire mesh to the rebar using binding wire. This creates a mesh cage that will be embedded in the mortar. The number of layers of wire mesh will depend on the size of your tank, but a minimum of three layers is generally recommended. More layers provide greater strength and crack resistance. Think of the wire mesh as the muscle and tendons of your tank – it provides the tensile strength to hold everything together. Ensure the framework is securely tied together and that there are no loose ends or gaps. A well-constructed framework is essential for a strong and durable tank.

Step 3: Mixing and Applying the Mortar

Now comes the crucial step of mixing and applying the mortar, which is the skin and flesh of your ferrocement tank. The mortar is what gives the tank its watertight seal and protects the reinforcing mesh. Start by mixing the mortar in a wheelbarrow or on a mixing board. The ideal mortar mix is typically a ratio of 1 part cement to 2 parts sand. Add water gradually until you achieve a smooth, workable consistency. The mortar should be thick enough to stick to the wire mesh but not so thick that it's difficult to spread. Test the consistency by scooping up a trowel full of mortar and turning the trowel upside down. The mortar should cling to the trowel without sliding off. Apply the mortar to the wire mesh framework using a trowel. Start by pressing the mortar firmly into the mesh, ensuring it penetrates all the layers. This is crucial for creating a strong bond between the mortar and the mesh. Apply the mortar in thin layers, working your way around the tank. Avoid applying too much mortar at once, as this can cause it to sag or crack. Allow each layer of mortar to partially dry before applying the next layer. This helps prevent cracking and ensures a strong, even coating. The total thickness of the mortar should be at least 1 inch, but thicker is better for larger tanks. Think of the mortar as the protective shell of your tank – it needs to be strong and watertight. Smooth the surface of the mortar with a trowel to create a smooth, even finish. This not only improves the appearance of the tank but also helps to prevent water from seeping into the mortar. Keep the mortar moist during the curing process by covering it with plastic sheeting or spraying it with water regularly. This helps the mortar to hydrate properly and reach its full strength. Curing is like giving your tank a long, healthy life – it ensures the mortar becomes as strong as possible.

Step 4: Curing the Tank

Curing is the often-overlooked but absolutely essential final step in building your ferrocement tank. It's like the aging process for a fine wine – it allows the mortar to reach its full potential and ensures a strong, durable tank. The curing process involves keeping the mortar moist for several days, typically 7 to 14 days. This allows the cement to hydrate properly and develop its strength. Start the curing process as soon as the mortar has set enough to prevent damage. There are several ways to cure your ferrocement tank. One common method is to cover the tank with plastic sheeting. This helps to trap moisture and prevent the mortar from drying out too quickly. Another method is to spray the tank with water several times a day. This keeps the surface moist and promotes proper hydration. You can also use wet burlap or hessian cloth to cover the tank. These materials hold moisture and help to keep the mortar damp. The key is to prevent the mortar from drying out too quickly. Rapid drying can lead to cracking and weaken the structure. Think of curing as giving your tank the time it needs to mature and strengthen. During the curing process, check the tank regularly for any signs of cracking. If you notice any cracks, repair them immediately with fresh mortar. Small cracks can quickly become larger problems if left unattended. The longer you cure your tank, the stronger it will be. A minimum of 7 days is recommended, but 14 days is even better. After the curing process is complete, your ferrocement tank is ready to be filled with water. But before you do, inspect the tank carefully for any leaks or imperfections. Make any necessary repairs before filling the tank. A well-cured ferrocement tank will provide you with a reliable water storage solution for many years to come.

Final Thoughts

Building a ferrocement tank is a rewarding DIY project that can provide you with a durable, cost-effective water storage solution. With careful planning, the right materials, and a little elbow grease, you can construct a tank that will serve your needs for years to come. Remember to take your time, follow the steps carefully, and don't be afraid to ask for help if you need it. Happy building, and enjoy your new water storage tank!