Optimization of solids composition in ferrock mortar

Ferrock is the commercial name given by the Dr Stone working with university of Arizona which holds the patent on this novel material. This is an alternative material developed for structural applications in place of concrete. In this paper, ferrock mortar is prepared with various solids such as iron powder, iron dust, cement and fly ash to establish the optimum combinations of solids for preparing the high strength ferrock systems. Iron dust in the form of powder (size less than 90 microns) and fine aggregate (size between 150 microns to 2.36mm) is used in the study to develop the iron carbonate matrix which is major binding material in ferrock. For the process of iron carbonation, carbon dioxide is prepared from the chemical reaction of sodium bicarbonate and acetic acid. Iron dust cubes are carbonated to form iron carbonation matrix upon fusion. This material has very high strength than the references cement mortar samples.