Types of Building Materials




  1. Thin Shell Structural Panels

          Method of cure: exposure within a chamber filled with CO2 or combustion exhaust

Ferrock has flexural strength five times greater than Portland cement. It also benefits more from the addition of reinforcing fibers of glass or steel and the difference with Portland cement then becomes even greater. Therefore it would work better for making fiber-reinforced thin shell structures or for ferrocement containing steel wire mesh. The thickness would be from 1 to 3 cm. Applications include pipe, water tanks, boat hulls, outdoor furniture, and structural panels for pre-fab buildings. Hydrogen is given off as a by-product and could be collected from the curing chamber.


  1. Porous Concrete Slabs

           Method of cure: internally with CO2 pumped through embedded perforated pipes

Ferrock works well as a binder for large aggregate without sand so that interconnected passageways allow for both gas and water to flow through easily. This makes for an efficient cure by pumping CO2 or combustion exhaust through a grid of interconnected perforated pipes that are embedded in the freshly poured mix. If the pipes are thick-walled they can take the place of rebar. After curing the porous slab is permeable by rain water, which can soak into the soil beneath rather than running off.


  1. Lightweight CO2– Entrained Blocks

         Method of cure: CO2 bubbles are sparged into the Ferrock mix to make a foam

 Blocks made of air-entrained Portland cement are becoming popular because they are lightweight, insulative, and fire-proof. The cement is filled with tiny bubbles of hydrogen produced by the addition of aluminum powder. The same kind of product can be made using CO2 and Ferrock. The trapped CO2 in the bubbles diffuses into the surrounding wet mix and causes it to harden by forming iron carbonate. The hydrogen bubbles given off by the reaction replace the CO2 in the bubbles. No extra CO2 is needed.


  1. Ferrock with Dry CO2– Saturated Sorbent

          Method of cure: CO2 is released from an amine-silica sorbent in the mix

 This type of product is still under development but has great promise as a method of making a carbon-negative binder that functions just like Portland cement. Water would be the only addition to the dry mix and then no further carbonation would be necessary. The wet Ferrock concrete would be poured and troweled like ordinary concrete then left to cure by the slow release of CO2 from the sorbent that is promoted by a mild acid.