 | This article may incorporate text from a large language model .(November 2025) |
Ferrock is a proprietary carbon-negative construction material made from recycled industrial waste, developed as an alternative to Portland cement.
| | This article may incorporate text from a large language model .(November 2025) |
Ferrock is a proprietary carbon-negative construction material made from recycled industrial waste, developed as an alternative to Portland cement.
Ferrock was developed in the early 2000s by Dr. David Stone, a doctoral student at the University of Arizona, during research into corrosion-resistant compounds. The material is trademarked and commercialized by Iron Shell Material Technologies under license from the University of Arizona. [1]
Production of Ferrock involves sourcing, grinding, and blending dry ingredients:
These materials are typically sourced from industrial waste streams and prepared as a dry mix. [2]
The curing process begins when water is added to the dry mix. This initiates a chemical reaction between iron compounds and carbon dioxide, forming iron carbonate — the compound responsible for Ferrock’s hardening and structural integrity. [3]
Unlike Portland cement, which requires high-temperature kilns for clinker production, Ferrock’s dry mix preparation avoids thermal processing. However, both materials cure at ambient temperatures once mixed with water — Portland cement through hydration, and Ferrock through carbonation. [4]
Ferrock has demonstrated high compressive strength, ranging from 34.5 MPa to 48 MPa, with some tests reaching up to 69 MPa. [5] It also exhibits improved flexural and tensile strength compared to conventional concrete. Its ductility and resistance to cracking under seismic stress, along with chemical inertness, make it suitable for marine and coastal applications. [6]
Ferrock’s environmental appeal lies in its use of recycled materials and its ability to sequester carbon dioxide during curing. Unlike Portland cement, whose production is energy-intensive and which emits significant CO2 during production, Ferrock’s process is considered more sustainable. [7] However, the availability of its key ingredients—steel dust and silica—is dependent on other industrial activities, which may limit its scalability. [3]
Ferrock has been used in small-scale construction projects such as pavers, bricks, and marine structures. Its resistance to saltwater corrosion makes it a candidate for coastal and underwater applications. [8] However, it has not yet been widely adopted for large-scale infrastructure due to cost and supply constraints.