How to Make an 8-Faucet Ferro-Cement Hand Washing Station

Created by Jackie Powell

Agua para la Salud

Nebaj, Guatemala

June 2010

What is Ferrocement?

A composite material--in this case using cement, rebar, and square mesh for enforcement

Once the frame of a structure is created using rebar and mesh, cement is applied

Rebar & mesh structure

Applying cement

Cement vs. Concrete

Our definitions of cement and concrete:Cement= sand + powdered cement + waterConcrete= gravel + sand + powdered cement +

water We suggest using 4000 PSI powdered

cement

Cement Mixture Proportions

Regular= 2 sand x 1 powdered cement using a 23 caliber sifter or ½” wire meshMix in a location with no rocks

Fino= 2 sand x 1 powdered cementUsing an extremely fine sifterMix in wheelbarrow

Liso= pure powdered cement + waterMix in wheelbarrow

Concrete Mixture ProportionsConcrete mixture varies

depending on size of gravel in your location

If ¾” grade gravel is available the mixture should be: 2.5 gravel x 2 sand x 1 powered cement

Otherwise, it is a good idea to ask nearby concrete company for the best mixture for the area

In Guatemala we use a 2x1x1 mixture

StepsPlacement &

LevelingMaking the BaseLaying Pipe Making the WallPlacing Drainage

Tubes & Clean Outs

Steps Continued

Finishing the WallMaking the 2000L

Tank Making Tank WallsCementing the Tank

Finishing TouchesFour Clean Outs35cm Sink BasinTank LidAdding Float

Placement & Leveling

Before construction, think of an ideal location for the hand washing station. If possible place in a location near bathrooms and kitchen and not in a location that will be needed for the construction of future classrooms, football fields, etc.

Level an area of at least 4x4 meters and determine an area to mix concrete and cement

4x4m

Making the Base

Base

Make a level wooden form for base measuring 3.2 x 3.2 meters and 15cm deep. Use a line level to level the wooden form

3.2x3.2 meters

15cm deep

3.2x3.2 meters sides

15cm deep

4.53m diagonal

63cm

3m

3m

Make rebar base structure 3 x 3 meters

To create: cut 12- 3m rebar pieces & 20 -65cm rebar pieces (creating squares measuring 25 x 25 cm). Tie each junction with tie wire.

25cm

25cm

Laying Pipe

Drainage 2” PVC- enters seepage pit or septic tank

Inflow ½” galvanized pipe- connects to water source

1.2m

1.5m

1.3m

Make a one-layer, 60cm thick layer of rock with 10 cm space between rock and wooden board frame.

60cm

Overflow & Clean Out 2” PVC- enters tank, placed above rock layer

1.2m

3.2m base

3.2m base

2.2m wall

2.2m w

all

150cm

150c

m

Overflow & Clean Out

165c

m

75cmDrainage

160cm

95cm

Aerial View of Pipe Placement in Relation to the Base

Entrance ½” galvanized pipe

35cm between tank and wall

Place the rebar frame on top of rock layer.

Fill in 60cm rock frame with concrete.

Making the Wall

WALL

CLEAN OUTS

Make rebar wall structure with 4 rings of #cm diameter, spaced 15cm apart bound with # verticals measuring 56cm spaced 27cm

27cm27cm27cm 27cm27cm 27cm27cm 27cm

15cm

15cm

15cm

Tie each junction with tie wire.

130cm diametro

40cm

5cm

Put together the larger metal wallform.Place the rebar structure inside of the outer

wall and adjust to ensure a 5cm space all around.

Place the wall form and rebar on top of the foundation.Fill with stones.

Placing Drainage Tubes & Clean Outs

Fill in with large rocks leaving 20cm from the rock to top of wooden form

20cm

20cm

Cross should be placed in center of frame

Attach four pieces of 75cm long 2” PVC tube from each opening of the cross

75cm

Then attach a T connection 25cm from wooden formAdd another piece of PVC tube until it reaches the end of

the formAttach drainage cap to T and make sure it is level with

top of wooden form should be 15cm from the top of wooden form

Drainage cap is made by drilling 5/16” holes in a 2” PVC cap

25cm

15cm

One drain should be connected to drainage tube using a cross connection

This drain should be angled slightly lower than other drains (17cm from top of wooden form) allowing for gray water to flow downhill into drainage tube

Drainage tube connecting to seepage pit or absorption tank

Four clean outs at each end of drain

Clean outs can be placed before or after pouring concrete. SEE SLIDES # 59&60

Glue all tubes together!

Angled slightly downhill

Aerial view of wall form

Inner Form

Rebar frame

Outer Form

10 cm10 cm

Put together the smaller metal form for the inner side of the wall and place on top of stones.

Fill in 10cm space with concrete and smooth top

Making the 2000L Tank

Tank

Faucets

Screw together circular metal form

Measurements for circular metal form

130cm diameter

15cm

5cm

40cm

40cm

40cm

40cm

40cm

50cm

50cm

50cm 50cm

Distances between faucet slots

Place circular metal form 35cm from inner wall of metal form, making sure it’s level.

35cm

Level!

Make two rebar rings to fit into circular metal form Rings should have a diameter of 128cm, using a 4.35m

piece of rebar allowing for 35cm of overlap should work nicely

Cut 16 pieces of 60cm long rebarTie 16 pieces onto rings 25cm apart

60cm rebar pieces tied to rebar rings

25cm apart

Fill in with rock and concrete to top of circular metal form

Place ½” galvanized steel faucet pipes in 8 openings at a slight angle

15cm

20cm

Fill in circular metal form with concrete and level off with wooden board leaving the center a bit lower than the edges

Level with board

Add a 140cm ½” galvanized pipe to existing pipe

Making the Tank Walls

Cut 16 pieces 2m rebar pieces Bend 40cm into a 40˚ angle

40˚ angle

40cm 2m

To check 40˚ angle, place bars 128cm apart and the opening should measure 50cm

128cm

50cm

Tie each 2m long bent rebar pieces to 60cm rebar stakes in tank base about 5cm of the 2m long piece should be pushed into base as

well

Tie in two places

Attach ½” elbow to connect ½” float valve

Make a 50cm diameter rebar circle and attach to top of tank

50cm

Make 6 rebar rings with diameters of 128cm each and tie them 25cm apart

Rebar rings placed 25cm apart

Also, add one rebar ring to top of tank

Adding rebar ring to top

Make several 100 -10cm long U-shaped wire pieces

Using U-shaped pieces to secure, place one layer of ¼” square mesh on rebar structure and tie securely with tie wire.

Inflow ½” galvanized pipe needs to be have an extra layer of mesh tied around it from the inside of the tank

Cementing the Tank

Add first layer 2x1 cement mixture from inside tank and allow to dry overnight

Pay special attention when covering this pipe with cement

Add layer of 2x1 cement on top of tank the next day

Apply three layers of cement on the outside of the tank allowing for time to dry in-between applications. Two regular layers and finish with a fino layer

Finish with a fino layer

Apply four more layers of cement inside the tank.Two regular, one fino, and one liso

Finishing Touches:Four Clean Outs

Clean Outs

2” male or female threaded adaptors with appropriate cap can be used for clean outs

Female with male cap Male with female cap

Take off metal forms and attach clean outs on each drain

35cm Sink Basin

Sink Basin

10cm wall

Tank

Fill in sink with cement

Make indentations to hold soap

35cm

Unscrew the circular metal form and allow it to expand in the sink basin. Fill in the corners with concrete.

Create sink area by filling in with cement. Cover the drainage caps with PVC or plastic to keep cement from entering.

10cm

The sink level should be about 1” higher than the drainage cap

1”

Tank Lid

Lid

Make a rebar lid structure and cover it with ¼” square mesh.

50cm

16cm17cm

50cm

17cm

7cm3cm

Cover with mesh

Lid rebar structure with mesh and tie wire

Cut out a cardboard circle the size of the opening, approx. 50cm in diameter

Lay down a piece of plastic and then lay down the rebar/mesh lid structure.

Fill in the rebar/mesh structure with the 3 to 1 cement mixture Use a trowel to make sure there are no air bubbles and the lid is

smooth and rounded. To make sure the lid is always placed on the tank correctly, make

an arrow on the lid and on the tank so they can always line up

Make marks so lid always fits tightly

After the lid has time to cure, remove plastic and cardboard

Clean off bottom of lid for a good fit

Adding Float

Connect float to elbow on entrance ½” galvanized pipe

Float

140cm entrance pipe

5cm galvanized pipe connecting elbow to float