What is Ferrock in Construction?

Ferrock is a sustainable alternative to traditional concrete made from recycled materials and steel dust, which absorbs carbon dioxide during its curing process, making it carbon-negative.

Let's discuss in detail the main queries related to the use of Ferrock in the construction industry.

How is Ferrock made?

Ferrock is made using waste steel dust (rich in iron), finely ground silica from recycled glass, and supplementary binders such as fly ash, metakaolin, and limestone. When mixed with water and exposed to CO₂, the iron particles oxidize and form iron carbonate—a solid binder. This reaction not only gives Ferrock its high strength but also makes it carbon-negative, since it absorbs CO₂ during the curing process.

Is Ferrock stronger than concrete?

Yes. Ferrock is significantly stronger than traditional Portland cement concrete. Laboratory studies show that Ferrock can achieve compressive strengths up to five times higher, with values ranging between 34.5 to 69 MPa compared to ordinary concrete’s 30–40 MPa. It also performs better in tensile and flexural strength tests, making it a promising candidate for structural applications.

What is Ferrock used for?

Ferrock is primarily used as a sustainable alternative in construction applications. It can be cast into slabs, blocks, pavers, walls, and sidewalks. Because of its resistance to corrosion and seawater, Ferrock is especially useful in marine and coastal construction, such as seawalls, breakwaters, and piers. Its high strength and flexibility also make it suitable for earthquake-resistant structures.

Is Ferrock Carbon Negative?

Ferrock becomes carbon-negative because during its curing process, it reacts with carbon dioxide (CO₂) from the atmosphere to harden, essentially locking CO₂ into its structure instead of releasing it like traditional cement, meaning it removes more CO₂ than it

What are the disadvantages of Ferrock?

Despite its benefits, Ferrock faces key challenges. It depends heavily on industrial by-products like steel dust and glass waste, which limits large-scale production. The material is still under research, and there are no established building codes or standards to regulate its widespread use. Additionally, sourcing consistent-quality by-products can be difficult, and costs may rise if demand increases.

Why is Ferrock not widely used?

Despite its environmental benefits, Ferrock is not yet mainstream because of limited commercial availability, higher production costs, and a lack of large-scale infrastructure experience. Additionally, construction industries are heavily invested in traditional Portland cement, making the transition slow.

With growing focus on sustainable construction and carbon-neutral goals, Ferrock has strong potential to become a green alternative to concrete, especially in specialty applications where carbon absorption and durability are prioritized.