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 + water

Concrete= 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 mesh

Mix in a location with no rocks

Fino= 2 sand x 1 powdered cement

Using an extremely fine sifter

Mix in wheelbarrow

Liso= pure powdered cement + water

Mix in wheelbarrow

Concrete Mixture Proportions Concrete 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 &

Leveling

Making the Base

Laying Pipe

Making the Wall

Placing Drainage

Tubes & Clean

Outs

Steps Continued

Finishing the Wall

Making the 2000L Tank

Making Tank Walls

Cementing the Tank

Finishing TouchesFour Clean Outs

35cm Sink Basin

Tank Lid

Adding 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

15cm deep

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 tankInflow ½” galvanized pipe-

connects to water source

1.2m

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

3.2

m b

as

e

2.2m wall

2.2

m w

all

150cm

150cm

Overflow

& Clean Out

165cm

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

15

cm

15

cm

15

cm

Tie each

junction

with tie

wire.

40cm

5cm

Put together the larger metal wall

form.

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 form

Add another piece of PVC tube until it reaches the end of the form

Attach 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 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

15cm

5cm

40cm

40cm

40cm

40cm

40cm

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 rebar

Tie 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

16cm

17cm

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