The sustainable materials developer, earth4Earth, has created a range of bricks that capture and permanently store carbon dioxide.

The bricks use Direct Air Capture (DAC) to extract CO2 from the air. This means buildings can be transformed into carbon sinks, just by using different bricks.

The first batch of bricks is now available in the UK, where they are being used in a range of pilot projects.

The bricks are made using excavated soil, which would otherwise go to landfill, combined with a unique earth4Earth (e4E) binder that enhances their durability and mechanical properties. The production of binders traditionally releases high levels of CO2 into the atmosphere. But earth4Earth has developed technology which drastically reduces the related CO2 emissions needed to make their binder and earth bricks.

“The binder is incredibly unique”, said Professor Theodore Hanein, Co-founder of earth4Earth.

“As with most traditional binders, ours is lime based. Lime is typically produced by heating limestone at temperatures of around 1,000C. Traditional production generates CO2 emissions from both the breakdown of the raw materials and the fossil fuels needed to achieve the high temperatures required.

“We have developed a unique lime production process that can be done at room temperature.

“All of the carbon produced during the manufacture of the e4E binder is also permanently stored in a solid form, rather than being released into the atmosphere as CO2.

“We are incredibly excited about how our work is going to help construction projects achieve net zero, and the huge difference it will make in restoring planetary health.”

The binder in the bricks captures and stores atmospheric CO2 quickly through a carbonation reaction. Once it is absorbed, the carbon further enhances the materials' properties.

The bricks are fully recyclable, as they can be crushed and made into new bricks or returned to the earth for crop growth at end-of-life. The carbon stays in the crushed material as it is chemically bound in the form of stable carbonates.

earth4Earth has developed a range of products to suit different requirements. There are N10, N20 and N30 bricks, which contain 10%, 20% and 30% of the e4E binder. As the percentage of the binder increases, so does the level of carbon absorption. Brick L10 also captures carbon but is made using conventionally produced lime, whilst L0 is an earth-based brick with no binder.

e4E was inspired by the Fujian Tulou, or earth buildings, found in China. They are made from rammed earth and other natural materials such as stone and wood. These buildings have stood for hundreds of years, withstanding even earthquakes and typhoons. They are naturally well-ventilated and provide excellent indoor air quality.

This legacy was combined with the team’s research and unique expertise to establish the earth4Earth ethos and create construction materials that are durable, breathable and genuinely good for people and planet.

e4E was founded in 2023 and has a Research and Development Centre in Sheffield and a factory in Wuhan, China. The manufacturing process was developed in China because of the company’s connections there and the time and cost savings. Now that the production line has been established, the bricks can be made anywhere and earth4Earth plans to begin production in the UK next year, creating at least 30 more jobs locally.

Lei Zhang, Director and Co-founder of earth4Earth, said: “We are planning to develop other types of brick and materials using the e4E binder in the future too. We want to provide practical solutions to the decarbonisation of the construction industry, and we believe that high-quality materials with a range of eco-credentials will deliver this.

"It has been great to collaborate with others on our journey, and we are keen to hear from anyone who would be interested in joining us to scale this innovative solution further."

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