A New Future for Concrete Masonry in Saudi Arabia?

Words: Peter Roberts, Dr. Ezzat, Robert Ferry

Spherical Block, LLC and Geopolymer International are working together to develop new concrete technologies and products for the construction industry. These two firms have been approached over the past few years by companies, individuals and investors from the Kingdom of Saudi Arabia (KSA) who are eager to bring this advanced concrete technology to KSA as it embarks upon extensive, ambitious new construction projects throughout the Kingdom. This is the first of a series of articles planned for Masonry Magazine over the next couple of years to describe the planned development and deployment of this new technology in KSA, the Gulf region and the Middle East/North Africa (MENA).

Spherical Block has developed, patented and launched innovative concrete block masonry technology to build roofs as masonry arched structures, to provide a complete masonry building envelope: extending the benefits of concrete block technology to the top of the roof. The benefits include high-strength, low cost, fire safety, rapid construction, long building life and increased thermal efficiency for lower heating and cooling requirements. Geopolymer International has developed geopolymer (GP) materials used to replace Ordinary Portland Cement (OPC) as a cementitious material for multiple applications. Spherical Block and Geopolymer International teamed up to produce concrete block using GP as a replacement for OPC. The initial tests went very well; the team produced high-strength CMUs at Southern Tier Concrete Products in Alfred, NY.

Additionally, the team is developing GP-based mortar and grout, with further testing planned. The team is also planning to test 3-dimensional concrete printing (3DCP) using GP in place of OPC which incorporates block. GP produces 80% less CO2 as compared to OPC; it is stronger and has a significantly longer lifespan than OPC; it is more resistant to corrosive chemicals than OPC; and it has better resistance to high temps and fire than OPC. The team is developing use of 3DCP with GP mortar and the placement of blocks with the MULE lift-assist by Construction Robotics.

All of these technologies are of interest to various companies and stakeholders in KSA. Spherical was initially contacted by companies from KSA through its work with projects funded by the National Science Foundation. This led to continuing dialog over the past few years, and growing interest from potential investors, stakeholders and project managers in KSA. It is important for the team to satisfy the requirements of SASO (Saudi Standards, Metrology and Quality Organization) the regulatory agency in KSA which establishes and enforces standards, regulations and quality control. The team is in talks with Dr. Mohamed Ezzat of Riyadh, who currently serves as president of ASCE (American Society of Civil Engineers) in KSA and has offered his expertise and laboratory resources to help meet SASO requirements.

Peter Roberts, president and founder of Spherical Block LLC is a graduate of Alfred University’s New York State College of Ceramics, and lives and works in Alfred, New York. He continues to work with Alfred University on NSF awards, as a guest lecturer, and as a teacher for Senior Class projects. Alfred University has a relationship with KSA where students come to Alfred, New York and study at the university and return to KSA with increased knowledge, skills and abilities which they developed at Alfred University’s Inamori School of Engineering. As part of their educational experience, Saudi students visit Mr. Roberts’ company to examine the work being done, and get a real-world exposure to construction currently being performed.

Over the past few years, the team has investigated the KSA market, including indigenous material available and structural designs and plans which are appropriate for KSA. The team is currently arranging to test sand from KSA for use in concrete and construction. This sand is typically wind-blown and as a result is rounded, making it less than ideal for use in concrete mix designs with OPC. As a result, KSA imports vast amounts of aggregate to help make concrete, mortars, and grouts. The team expects to be able utilize the sand from KSA by using proprietary mix designs, including GPs. These are important steps to help the Kingdom become more self-sufficient by using its abundant supply of sand for producing concrete, mortar, and grout.

Spherical Block enjoys a history of working with Besser Company. Besser manufacturers molds to produce Spherical Block and provides technical assistance. Besser block manufacturing equipment is currently in use in KSA by various producers. In the future, the team may perform developmental work using the production facility and testing lab at the World Center for Concrete Technology (WCCT) in Alpena, Michigan, where Besser’s global headquarters are located.

The team has initial designs for homes in KSA by architect Robert Ferry LEED AP, BD+C of the architectural firm Studied Impact. Mr. Ferry has spent years in the Middle East, including KSA and UAE, among other countries in MENA. His familiarity with the architectural vocabulary of the Middle East brings an informed design sense to the projects currently being planned. Mr. Ferry’s knowledge of appropriate materials take advantage of the thermal mass benefits of the team’s materials and design configurations to provide beautiful architecture which resonates with Saudi aesthetics and bring the beauty of block to light.

The team will document our progress on this exciting new venture, and to provide additional articles for Masonry Magazine over the next few years as progress is made. Keep your eyes on this publication for updates as this project evolves on the exciting new realm of masonry design and construction throughout the Middle East and Saudi Arabia.

A New Future for Concrete Masonry in Saudi Arabia?

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