1. Can Ferrock be a substitute for Portland cement?
No, not a general substitute at anything like the volume that Portland cement is used. It took 200 years for modern cement production to develop into the massive global industry it is today. Just retooling the plants for a different kind of product like Ferrock would be a daunting technical and financial challenge, let alone developing large scale and competitive manufacturing plants. Because it is so fully integrated into the building industry Portland cement will likely be used for at least decades to come despite its high carbon emissions. There are methods being developed to help shrink its footprint by companies like Solidia and CarbonCure. Others such as Carbicrete are producing true alternative cements.
2. Is Ferrock commercially available anywhere?
No, we would need a large, mature company to manufacture and distribute it.
3. I am building a house (or driveway or something else). Can I use Ferrock for this?
Thanks for the interest, but unfortunately Ferrock is not yet available for such construction projects.
4. So what can Ferrock be used for?
Ferrock might be able to find markets for certain specific applications where it should do better than Portland cement. These include coastal and marine applications because saltwater can be used in the mix and the resulting Ferrock-based concrete is more stable in seawater. Also, Ferrock does not break down into a powder like Portland does when exposed to high heat (above 600 C) like from a prolonged and intense fire. Finally, because research has shown that it has greater flexural strength and crack resistance, Ferrock should be better for thin shell structures made using the ferrocement method, in which mortar is troweled over one or more layers of steel wire mesh as reinforcement. In other words, Ferrock will need to start as a specialized product in a niche market. Let us know if you have a specific idea.
5. How will Ferrock and Polymiron eventually become commercially available?
We are looking for an existing company to acquire the patents for these materials and commercialize them as their own products. Iron Shell is a small R&D startup and does not have the resources to bring new building materials to market.