Bio-concrete products, equipment and manufacturing methods

Abstract

This document describes a novel method, reusable frame, and system for producing building materials, structural materials, and concrete. The method includes: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; allowing a first fluid containing a binding agent to flow through the frame-like plurality of aggregate particles, or allowing the first fluid to flow through the frame-like plurality of aggregate particles at a pressure above atmospheric pressure, wherein the fluid is introduced into the frame from one direction such that the flow direction is opposite to gravity; and reacting the binding agent with biological organisms and / or enzymes contained within the fluid or the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

Description

Priority requirements

[0001] This application claims the benefit and priority of U.S. Provisional Application No. 63 / 604,079, filed November 29, 2023, which is incorporated herein by reference in its entirety. Background Technology

[0002] Biocement technology offers cost-effective, high-strength building materials, structural materials, and concrete that significantly reduce carbon footprint compared to traditional building materials and concrete. Therefore, methods for producing building materials, structural materials, and concrete in various shapes, as well as reusable frames and systems, are needed for different building purposes and applications. Summary of the Invention

[0003] Biocement technology utilizes organisms (such as enzymes or microorganisms) to improve the mechanical and structural properties of building materials. In some cases, through microbial-induced calcium carbonate precipitation (MICP), microorganisms can react with chemical components to produce minerals in the form of organic-inorganic compounds, which can act as binders in building materials such as building aggregates including sand, gravel, and crushed stone particles.

[0004] Biological structures may comprise structures or building materials constructed using one or more biological processes (e.g., using enzymes or microorganisms). If the building material constructed using one or more biological processes includes living microorganisms, the resulting building material may contain living building materials. Building materials made using one or more biological processes may or may not include living biological materials or microorganisms. Building materials made using one or more biological processes may or may not include residues of biological materials or microorganisms (e.g., encapsulated cells (e.g., in calcite), or cavities left by their decomposition).

[0005] According to some implementation schemes, the technical benefits of the systems and methods for manufacturing biological structures disclosed herein include reduced manufacturing time, lower manufacturing costs, increased production of building materials, improved freeze-thaw performance, increased flexural strength of building materials, increased density, reduced porosity, and increased compressive strength of building materials.

[0006] A key technical advantage of the methods and systems described herein is their ability to fabricate a wide range of complex and non-standard 3D shapes, such as angular shapes (e.g., L-shaped obstacles), artistic shapes, spheres, stars, and more. Furthermore, the methods and systems described herein can also fabricate building units that are significantly larger than any structural units previously demonstrated in MICP-based technologies.

[0007] In building material production, pumping a fluid containing a binder agent through or flowing in one direction through aggregate particles, opposite to gravity, and / or at pressures above atmospheric pressure, offers advantages including improved freeze-thaw performance, increased flexural strength, increased density, reduced porosity, and increased compressive strength. In building material production, pumping a fluid containing a binder agent into multiple inlets and / or outlets within a frame at pressures above atmospheric pressure also offers advantages including improved freeze-thaw performance, increased flexural strength, increased density, reduced porosity, and increased compressive strength. In bio-binding processes, such as those requiring delivery of reagents from the outside of the form to reaction sites within the pores, a problem in producing complex shapes is that elements of the shape (and corresponding volumes within the frame), such as protrusions, cavities, and convex surfaces, can lead to air gaps or areas of slow binder agent flow, resulting in inconsistencies in the finished product. Multiple inlets and / or outlets within the frame, combined with pumped flow to supply the binder agent, solve this problem and allow for the production of a wide variety of complex shapes. The technical advantages of detecting whether the back pressure of the fluid flowing through aggregate particles exceeds a threshold back pressure, and / or detecting whether the change in the fluid's conductivity exceeds a threshold amount, and adjusting the pressure or flow rate of the fluid flowing through the aggregate particles accordingly, include: improving the flexural strength of building materials, increasing density, reducing porosity, and increasing the compressive strength of building materials. One problem caused by excessively high initial pressure when allowing a fluid containing a binding agent to flow through aggregate particles is that it may damage the building materials due to water jets or localized erosion near the inlet and / or outlet of the aggregate particle frame or support structure. Other technical advantages can also be achieved through various implementations of the disclosed technology.

[0008] This document provides a method for producing building materials in various embodiments, the method comprising: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; allowing a first fluid containing a cementing agent to flow through the frame-like plurality of aggregate particles; and reacting the cementing agent with biological organisms and / or enzymes contained in the first fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

[0009] This document provides a method for producing building materials in various embodiments, the method comprising: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; pumping a first fluid containing a cementing agent through the frame-like plurality of aggregate particles; and reacting the cementing agent with biological organisms and / or enzymes contained in the first fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

[0010] This document provides a method for producing building materials in various embodiments, the method comprising: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; allowing a first fluid containing a cementing agent to flow through the frame-like plurality of aggregate particles, wherein the fluid is introduced into the frame in one direction such that the flow direction is opposite to gravity; and reacting the cementing agent with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles, the reaction time being sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

[0011] This document provides a method for producing building materials in various embodiments, the method comprising: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; allowing a first fluid containing a cementing agent to flow through the frame-like plurality of aggregate particles at a pressure above atmospheric pressure; and reacting the cementing agent with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

[0012] This document provides a method for producing building materials in various embodiments, the method comprising: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; substantially venting air from the gaps between the frame-like plurality of aggregate particles; allowing a first fluid containing a binding agent to flow through the frame-like plurality of aggregate particles; and reacting the binding agent with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

[0013] This document provides a method for producing building materials in various embodiments, the method comprising: compacting a plurality of aggregate particles in a frame to reduce the volume of void space between adjacent particles of the plurality of aggregate particles; allowing a first fluid containing a cementing agent to flow through the void space of the plurality of aggregate particles; and reacting the cementing agent with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles, the reaction time being sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

[0014] In some implementations, the first fluid flows through a frame of aggregate particles by entering through the lower surface of the frame and exiting through the upper surface of the frame.

[0015] In some implementations, fluid flows through multiple aggregate particles at a first pressure greater than atmospheric pressure.

[0016] In some implementations, fluid flows through multiple aggregate particles at a second time at a second pressure, which is greater than the first pressure.

[0017] In some implementations, a second fluid containing a binding agent is flowed through a framework of aggregate particles before, during, or after the reaction.

[0018] In some embodiments, one or more binding agents (e.g., one or more enzymes, organisms, urea, etc.) are added to the aggregate before it is added to the frame (i.e., pre-inoculated aggregate). One or more binding agents may be added during aggregate mixing / blending (e.g., in a cement mixer or other mixing apparatus).

[0019] In some implementations, one method involves recirculating a first or second fluid through the frame, repeating the cycle multiple times.

[0020] In some implementations, each cycle of multiple cycles increases the degree of consolidation of multiple aggregate particles.

[0021] In some implementations, the fluid is recirculated through the frame for a total of at least three cycles (e.g., at least five or at least ten cycles).

[0022] In some embodiments, the volume of the first or second fluid is about 50% to about 500% of the frame volume (e.g., about 75% to about 150%).

[0023] In some embodiments, the cementing agent contained in the first fluid comprises a biological organism (or its spores) and / or an enzyme.

[0024] In some embodiments, the cementing agent contained in the second fluid contains nutrients that promote the activity of biological organisms and / or enzymes.

[0025] In some embodiments, the cementing agent contained in the first fluid contains nutrients that promote the activity of biological organisms and / or enzymes.

[0026] In some embodiments, the cementing agent contained in the first fluid does not contain nutrients that promote the activity of biological organisms and / or enzymes.

[0027] In some embodiments, the cementing agent comprises a biological organism (or its spores), an enzyme, urea (and / or its derivatives), a calcium salt (e.g., CaCl2), a nutrient, or a combination of two or more of these substances.

[0028] In some implementations, multiple aggregate particles comprise a mixture of sand and gravel.

[0029] In some implementations, the sand and gravel mixture contains 1-99% sand and 1-99% gravel by volume.

[0030] In some embodiments, the sand and gravel mixture comprises 55-75% sand and 25-45% gravel by volume (e.g., the sand and gravel mixture comprises 66% sand and 34% gravel).

[0031] In some implementations, multiple aggregate particles consist primarily of a mixture of sand and gravel.

[0032] In some embodiments, the average particle size of the sand is at least 10 times smaller than the average particle size of the gravel (e.g., at least 20 times, 50 times, or 100 times smaller).

[0033] In some implementations, a method also includes adding reinforcing material (e.g., steel bars, glass fiber reinforced bars, or glass fiber bundles) into the frame before or simultaneously with the addition of multiple aggregate particles.

[0034] In some implementations, one method also includes settling multiple aggregate particles into the mold cavity of the frame.

[0035] In some implementations, settling is achieved by pressing multiple aggregate particles and / or applying vibration to multiple aggregate particles to reduce the volume of void space within the mold.

[0036] In some implementations, sedimentation occurs while multiple particles are drying.

[0037] In some implementations, sedimentation occurs when multiple particles are solvated.

[0038] In some implementations, sedimentation is carried out at least in part by applying a pressurized solvent (e.g., water) to the particles at a pressure configured to increase the bulk density of the particles.

[0039] In some implementations, the pressure of any fluid flow applied to the frame-like multiple particles is at least about 1 psi (e.g., at least about 5, 10, 20, 50, or 100 psi).

[0040] In some embodiments, the produced building material has a compressive strength of at least about 3,000 psi (e.g., at least 4,000 psi or at least 6,000 psi), and / or wherein the building material remains undamaged after 25 cycles of a freeze-thaw test according to EN 14617-5. In some embodiments, the bio-concrete building material produced by the methods or systems described herein has a compressive strength of about 900 psi to about 12,000 psi. In some implementations, bio-concrete building materials have strengths of approximately 900 psi to approximately 1,000 psi, approximately 900 psi to approximately 1,100 psi, approximately 900 psi to approximately 1,200 psi, approximately 900 psi to approximately 1,300 psi, approximately 900 psi to approximately 1,400 psi, approximately 900 psi to approximately 1,600 psi, approximately 900 psi to approximately 1,800 psi, approximately 900 psi to approximately 2,000 psi, approximately 900 psi to approximately 2,500 psi, approximately 900 psi to approximately 3,000 psi, approximately 900 psi to approximately 3,500 psi, approximately 1,000 psi to approximately 1,100 psi, approximately 1,000 psi to approximately 1,200 psi, approximately 1,000 psi to approximately 1,300 psi, approximately 1,000 psi to approximately 1,400 psi, and approximately 1,000 psi. psi to approximately 1,600 psi, approximately 1,000 psi to approximately 1,800 psi, approximately 1,000 psi to approximately 2,000 psi, approximately 1,000 psi to approximately 2,500 psi, approximately 1,000 psi to approximately 3,000 psi, approximately 1,000 psi to approximately 3,500 psi, approximately 1,800 psi to approximately 2,000 psi, approximately 1,800 psi to approximately 2,500 psi, approximately 1,800 psi to approximately 3,000 psi, approximately 1,800 psi to approximately 3,500 psi, approximately 2,000 psi to approximately 2,500 psi, approximately 2,000 psi to approximately 3,000 psi, approximately 2,500 psi to approximately 3,000 psi, approximately 2,500 psi to approximately 3,500 psi, approximately 2,500 psi to approximately 3,500 psi. psi or approximately 3,000 psi to approximately 3,500 psi, approximately 1,100 psi to approximately 4,200 psi, approximately 2,100 psi to approximately 4,300 psi, approximately 2,100 psi to approximately 5,400 psi, approximately 2,100 psi to approximately 5,600 psi, approximately 2,100 psi to approximately 4,800 psi, approximately 2,100 psi to approximately 8,000 psi, approximately 1,100 psi to approximately 7,500 psi, approximately 4,100 psi to approximately 10,000 psi, approximately 5,100 psi to approximately 11,500 psi, approximately 6,200 psi to approximately 7,300 psi, approximately 5,200 psi to approximately 9,400 psi, approximately 6,200 psi to approximately 9,600 psi, approximately 5,200 psi to approximately 11,800 psi, approximately 1,200 psi to approximately 10,000 psi, approximately 2,000 psi to approximately 10,000 psi, approximately 3,000 psi to approximately 10,000 psi, approximately 4,000 psi to approximately 10,000 psi, approximately 5,000 psi to approximately 10,000 psi, approximately 6,000 psi to approximately 10,000 psi, approximately 7,000 psi to approximately 10,000 psi, approximately 8,000 psi The compressive strength is approximately 1,000 psi to about 10,000 psi, approximately 9,000 psi to about 10,000 psi, or approximately 10,200 psi to about 12,000 psi. In some embodiments, the bio-concrete building material has compressive strengths of approximately 1,000 psi, approximately 2,000 psi, approximately 3,000 psi, approximately 4,000 psi, approximately 5,000 psi, approximately 6,000 psi, approximately 7,000 psi, approximately 8,000 psi, approximately 9,000 psi, approximately 10,000 psi, approximately 11,000 psi, or approximately 12,000 psi. In some implementations, the bio-concrete building material has a compressive strength of at least 900 psi, 1,000 psi, 2,000 psi, 3,000 psi, 4,000 psi, 5,000 psi, 6,000 psi, 7,000 psi, 8,000 psi, 9,000 psi, 10,000 psi, 11,000 psi, or 12,000 psi.

[0041] In some implementations, the biological organism is an organism (or its spores) that produces urease.

[0042] In some implementations, the organism that produces urease is *Bacillus pasteurellii* (…). sporosarcina pasteurii ).

[0043] In some implementations, the enzyme is urease.

[0044] In some implementations, the method includes, essentially prior to the reaction, removing air from the void spaces between the multiple aggregate particles in a frame-like structure.

[0045] In some implementations, the reaction binds adjacent particles together via calcium carbonate bridges, thereby forming a building material.

[0046] This document provides, in various embodiments, a reusable frame for producing precast bioconcrete building materials, the frame comprising: a plurality of panels configured to: (i) be temporarily fixed together during curing of the precast bioconcrete building material to form a fluidly connected system, and (ii) be released to allow demolding of the precast building material from a cavity formed when the plurality of panels are fixed together; a binder inlet; a binder outlet; wherein the cavity formed when the panels are fixed together has a volume of at least 50 L (e.g., at least 100 L or at least 1000 L), the binder inlet being located on at least one of the plurality of panels and configured to be fluidly connected to the cavity when the plurality of panels are temporarily fixed, and the binder outlet being located on at least one of the plurality of panels and configured to be fluidly connected to the cavity when the plurality of panels are temporarily fixed.

[0047] In some implementations, the bonding agent inlet is configured to be located on a panel lower than the bonding agent outlet when multiple panels are temporarily fixed.

[0048] In some implementations, the binder inlet and / or binder outlet are configured to allow pressurization of fluid within the mold cavity of the reusable frame.

[0049] In some implementations, the reusable frame includes one or more vents configured to allow air to escape from the mold cavity.

[0050] In some implementations, one or more vents include a check valve that allows gas flow but prevents liquid flow in the same direction, for example, by using a buoyancy element such as a floating ball valve.

[0051] In some implementations, one or more vents are provided on one or more surfaces of the reusable frame (e.g., on the top surface, one or more sides, or a combination thereof, such as on one or more panels of a plurality of panels).

[0052] In some implementations, the multiple panels include at least one patterned panel, the pattern being configured to alter the aesthetic appearance of one or more surfaces of the prefabricated building material.

[0053] In some implementations, multiple panels are configured modularly, which allows for the manufacture of multiple types or quantities of precast bioconcrete material using the same reusable frame.

[0054] In some implementations, the precast bioconcrete materials produced by the frame are: various paving bricks, L-shaped walls, modular wall panels, and / or Jersey barriers.

[0055] In some embodiments, a system for producing precast bioconcrete building materials includes a reusable frame, fluid manifold, and pump as described in any of the foregoing embodiments.

[0056] In some implementations, the pump is fluidly connected to a fluid manifold, a reusable frame's cementing agent inlet, and / or cementing agent outlet.

[0057] In some implementations, the system also includes a recirculation tank configured to recirculate fluid through a reusable frame.

[0058] In some implementations, the system also includes a reagent storage tank configured to supply fresh bonding reagent to a recycling tank, to the mold cavity of a reusable frame, or both.

[0059] In some implementations, the system also includes one or more effluent storage tanks configured to accumulate waste liquid and / or fluids from which the binding agent has been depleted.

[0060] In some implementations, the system is configured to perform the methods of any of the implementations.

[0061] In some implementations, building materials are manufactured using methods found in any of these implementations.

[0062] This summary is provided to briefly describe some aspects of the disclosed technology in a simplified form, which will be further described in the following detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to embodiments that address any or all of the shortcomings pointed out in any part of this disclosure. Attached Figure Description

[0063] The features and advantages of this disclosure can be obtained by referring to the following illustrative description of embodiments utilizing the principles of this disclosure, along with the accompanying drawings, in which: Figure 1A-1B A 7-unit paving brick frame used for manufacturing paving bricks was displayed. Figure 1A A top view of the frame is shown as the aggregate mixture is filled into the mold. Figure 1B This shows the top chamber and the side that was removed after the packing was completed.

[0064] Figure 2 The feeding scheme for producing paving bricks is shown.

[0065] Figure 3A The location of the sample cut from the paving bricks and the results of each test are shown.

[0066] Figure 3B-3C The results of the compressive strength and flexural strength tests are described.

[0067] Figures 4A-4B The frame used to create a prefabricated component of approximately 100 square feet is shown. Figure 4A The top and bottom air chambers of the panel mold are shown. Figure 4B An exploded view of the paving brick production system is shown.

[0068] Figures 5A-5B A frame for manufacturing L-shaped wall barriers is shown. Figure 5A The design of the L-shaped wall barrier frame is shown. Figure 5B The final L-shaped wall barrier product was showcased.

[0069] Figure 6 The final modular wall panel product was showcased.

[0070] Figures 7A-7B The final New Jersey-style fencing product and the fiberglass reinforced steel elements within the New Jersey-style fencing mold were showcased.

[0071] Figures 8A-8B The column frame and the fiberglass reinforced steel elements before insertion into the column mold are shown.

[0072] Figure 8C The image shows the removal of a silicone mold (top) from the surface of the final product (bottom).

[0073] Figure 9A An implementation scheme for a system that uses one or more bio-bonding processes to manufacture building materials is described.

[0074] Figure 9B An implementation scheme for various components of a computing system is described.

[0075] Figure 9C-9E A flowchart describing an implementation scheme for the manufacturing process of building materials is presented. Detailed Implementation

[0076] All terms are intended to be understood as such by those skilled in the art. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0077] The following definitions are supplementary to those defined in the art and are specific to the present application, and should not be attributed to any related or unrelated cases, such as any jointly owned patents or applications. While any methods and materials similar to or equivalent to those described herein may be used in the practice of testing this disclosure, preferred materials and methods are described hereafter. Therefore, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0078] The terminology used herein is for descriptive purposes only and is not intended to be limiting. In this application, the use of the singular includes the plural unless explicitly stated otherwise. Unless the context clearly indicates otherwise, the singular forms “an” and “described” are intended to include the plural forms as well, as used herein.

[0079] The terms “about” or “approximately” can mean within an acceptable margin of error for a particular value as determined by a person skilled in the art, depending in part on how the value is measured or determined, i.e., the limitations of the measurement system. For example, “about” can mean within one or more standard deviations, according to practice in the art. Alternatively, “about” can mean a range of up to 20%, up to 15%, up to 10%, up to 5%, or up to 1% of a given value. Or, particularly in biological systems or processes, the term can mean within an order of magnitude, within 5 times, or within 2 times a value. When a particular value is described in the application and claims, unless otherwise stated, the term “about” should be assumed to mean within an acceptable margin of error for that particular value.

[0080] As used in this specification and claims, the terms “comprising” (and any form of inclusion, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of inclusion, such as “includes” and “include”), or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unmentioned elements or method steps. It is contemplated that any embodiment discussed in this specification can be implemented by any method or composition of this disclosure, and vice versa. Furthermore, the compositions of this disclosure can be used to implement the methods of this disclosure.

[0081] In this specification, references to "some embodiments," "an embodiment," "an embodiment," or "other embodiments" mean that a specific feature, structure, or characteristic described in connection with the said embodiment is included in at least some embodiments of this disclosure, but not all embodiments. To facilitate understanding of this disclosure, several terms and phrases are defined below.

[0082] It should be understood that the ranges provided in this document are abbreviated forms of all values ​​within that range. For example, the range 1 to 50 should be understood to include any number, combination of numbers, or subrange of any group consisting of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50, as well as all intermediate decimal values ​​between the aforementioned integers, such as 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, and 1.9. For subranges, "nested subranges" extending from either endpoint of the range are particularly considered. For example, nested subranges of the exemplary range 1 to 50 may include 1 to 10, 1 to 20, 1 to 30 and 1 to 40 in one direction, or 50 to 40, 50 to 30, 50 to 20 and 50 to 10 in another direction.

[0083] The terms “optional” or “optionally” indicate that the event or situation described below may, but not necessarily, occur, and that the description includes both the possibility that the event or situation occurs and the possibility that it does not.

[0084] Some embodiments described herein consider numerical ranges. When a range exists, the range includes the range endpoints. Additionally, each subrange and value within a range exists as explicitly stated. The terms “about,” “approximately,” or “substantially” can mean within an acceptable margin of error for a particular value, which may depend in part on how the value is measured or determined, for example, limitations of the measurement system. For example, “about” can mean within one or more standard deviations according to practice in the art. Alternatively, “about” can mean a range of up to 20%, up to 10%, up to 5%, or up to 1% of a given value. When a particular value is described in the application and claims, unless otherwise stated, it may be assumed that the term “about” means within an acceptable margin of error for that particular value.

[0085] As used herein, the term "construction material" or "construction materials" generally refers to an article comprising elements or sub-assemblies bonded together by cementitious connectors or bridging agents with adhesive properties. The connectors or bridging agents in a construction material may be calcium carbonate. Construction materials, as used herein, are single physical objects of a defined shape that can be incorporated into a building, structure, or work. Specifically, construction materials as used herein include biocement products. Examples of biocement products include, but are not limited to, articles made from bio-concrete, biocement-coated aggregates, etc.

[0086] As used herein, the term "bridged calcium carbonate" generally refers to calcium carbonate that connects to and / or contributes to the bonding of at least two parts (e.g., aggregate particles) together. Bridged calcium carbonate, together with the at least two parts, provides a continuous assembly comprising the at least two parts and the bridging calcium carbonate. Calcium carbonate can be a solid, such as a precipitate. Calcium carbonate can be formed by the reaction of calcium ions with carbonate ions in an aqueous solution, wherein the resulting calcium carbonate is incorporated into a blocky composite material comprising calcium carbonate and aggregate particles. Even if calcium carbonate does not bridge or connect two aggregate particles, it can still be considered bridged if it contributes to enhancing the overall bond strength, for example, by further structurally reinforcing the bridging or connecting calcium carbonate blocks that are directly or indirectly connected.

[0087] As used herein, the term "unbridged calcium carbonate" generally refers to calcium carbonate that is not bonded to at least two parts (e.g., aggregate particles) or contributes to the bonding of at least two parts together. Unbridged calcium carbonate can be a precipitate bonded to only one part (e.g., aggregate particles) or a precipitate not bonded to any aggregate particles. Unbridged calcium carbonate can bond to at most one part.

[0088] As used herein, the term "aggregate particles" generally refers to cement components that can be bound together according to the disclosures herein (e.g., the compositions, systems, and methods described herein). Aggregate particles may contain materials as described herein and / or used in masonry, such as materials that would be used by someone skilled in the art.

[0089] As used herein, the terms “aggregate” or “aggregate particles” are used interchangeably and generally refer to any type of particulate matter that can be bonded together by biocement binders or bridging agents to form larger particles or consolidated solids. Non-limiting examples of aggregates include sand, crushed stone, tailings, or combinations thereof.

[0090] In some implementations, fine-grained limestone particles can be used instead of pond aggregate in the building materials. The aggregate mixture may include a mixture of sand, gravel, crushed stone and / or fine-grained limestone particles with a diameter of less than 250 micrometers or less than 100 micrometers. The average particle size (or maximum cross-sectional size, or minimum cross-sectional size) of fine-grained limestone can be less than 250 micrometers, for example, between 1 micrometer and 250 micrometers (e.g., between 1 micrometer and 2 micrometers, between 1 micrometer and 5 micrometers, between 2 micrometers and 4 micrometers, between 2 micrometers and 3 micrometers, between 1 micrometer and 10 micrometers, between 2 micrometers and 10 micrometers, between 5 micrometers and 10 micrometers, between 1 micrometer and 20 micrometers, between 10 micrometers and 20 micrometers, between 1 micrometer and 100 micrometers, between 10 micrometers and 100 micrometers, between 1 micrometer and 50 micrometers, between 1 micrometer and 50 micrometers, between 1 micrometer and 50 micrometers, between 20 micrometers and 40 micrometers, between 20 micrometers and 50 micrometers, between 25 micrometers and 50 micrometers, between 50 micrometers and 100 micrometers, between 30 micrometers and 100 micrometers, between 40 micrometers and 80 micrometers, between 25 micrometers and 75 micrometers, between 50 micrometers and 150 micrometers, between 75 micrometers and...). Between 150 micrometers, between 80 micrometers and 120 micrometers, between 125 micrometers and 225 micrometers, between 150 micrometers and 250 micrometers, between 175 micrometers and 225 micrometers, between 180 micrometers and 220 micrometers, between 200 micrometers and 220 micrometers, or between 200 micrometers and 250 micrometers), for example, less than 225 micrometers (e.g., less than 200 micrometers, less than 150 micrometers, less than 100 micrometers, less than 50 micrometers, less than 20 micrometers, less than 10 micrometers, less than 5 micrometers, or less than 2 micrometers), for example, about 1 micrometer, about 2 micrometers, about 5 micrometers, about 10 micrometers, about 15 micrometers, about 20 micrometers, about 30 micrometers, about 40 micrometers, about 50 micrometers, about 60 micrometers, about 70 micrometers, about 80 micrometers, about 90 micrometers, about 100 micrometers, about 120 micrometers, about 150 micrometers, about 175 micrometers, about 200 micrometers, about 220 micrometers, or about 250 micrometers.The median particle size (or maximum cross-sectional size, or minimum cross-sectional size) of fine-grained limestone can be less than 250 micrometers, for example, between 1 micrometer and 250 micrometers (e.g., between 1 micrometer and 2 micrometers, between 1 micrometer and 5 micrometers, between 2 micrometers and 4 micrometers, between 2 micrometers and 3 micrometers, between 1 micrometer and 10 micrometers, between 2 micrometers and 10 micrometers, between 5 micrometers and 10 micrometers, between 1 micrometer and 20 micrometers, between 10 micrometers and 20 micrometers, between 1 micrometer and 100 micrometers, between 10 micrometers and 100 micrometers, between 1 micrometer and 50 micrometers, between 1 micrometer and 50 micrometers, between 1 micrometer and 25 micrometers, between 20 micrometers and 40 micrometers, between 20 micrometers and 50 micrometers, between 25 micrometers and 50 micrometers, between 50 micrometers and 100 micrometers, between 30 micrometers and 100 micrometers, between 40 micrometers and 80 micrometers, between 25 micrometers and 75 micrometers, between 50 micrometers and 150 micrometers, between 75 micrometers and...). Between 150 micrometers, between 80 micrometers and 120 micrometers, between 125 micrometers and 225 micrometers, between 150 micrometers and 250 micrometers, between 175 micrometers and 225 micrometers, between 180 micrometers and 220 micrometers, between 200 micrometers and 220 micrometers, or between 200 and 250 micrometers), for example, less than 225 micrometers (for example, less than 200 micrometers, less than 150 micrometers, less than 100 micrometers, less than 50 micrometers, less than 20 micrometers, less than 10 micrometers, less than 5 micrometers, or less than 2 micrometers), for example, about 1 micrometer, about 2 micrometers, about 5 micrometers, about 10 micrometers, about 15 micrometers, about 20 micrometers, about 30 micrometers, about 40 micrometers, about 50 micrometers, about 60 micrometers, about 70 micrometers, about 80 micrometers, about 90 micrometers, about 100 micrometers, about 120 micrometers, about 150 micrometers, about 175 micrometers, about 200 micrometers, about 220 micrometers, or about 250 micrometers. In some embodiments, fine-grained limestone can have a particle size distribution of 100%, 90%, 80%, 75%, 70%, 60%, 50%, 40%, 30%, 25%, 15%, or 10% of particles smaller than 20 micrometers. Fine-grained limestone can have a particle size distribution where 100% of the particles can pass through sieves with mesh sizes of 2000 micrometers, 125 micrometers, 63 micrometers, or 45 micrometers. Fine-grained limestone can have a particle size distribution where 99% of the particles can pass through sieves with mesh sizes of 250 micrometers, 20 micrometers, or 10 micrometers. Fine-grained limestone can have a particle size distribution where 97% of the particles can pass through sieves with mesh sizes of 125 micrometers, 63 micrometers, or 10 micrometers. Fine-grained limestone can have a particle size distribution where 50% of the particles can pass through sieves with mesh sizes of 2 micrometers. Fine-grained limestone can have a particle size distribution where 18% of the particles can pass through sieves with mesh sizes of 1 micrometer.The Mohs hardness of fine-grained limestone may be between 2 and 4 (e.g., 2-2.2, 2-2.4, 2-2.5, 2.2.6, 2-2.8, 2-2.9, 2-3, 2-3.2, 2.2-3.2, 2.5-3.5, 2.5-3, 2.8-3.8 or 3-4, e.g., about 2.2, 2.5, 2.7, 2.8, 3, 3.2, 3.5 or 4). The porosity of fine-grained limestone can range from 0.1% to 40% (e.g., 0.1% to 1%, 1% to 10%, 10% to 40%, e.g., 20% to 40%, 25% to 40%, 30% to 40%, 35% to 40%, or 38% to 40%). Alternative fine-grained components, such as those having the particle size distribution described herein, may include wollastonite, bentonite, gypsum (e.g., calcined gypsum), pond fines, volcanic ash (e.g., fly ash or volcanic ash), etc. Some fine-grained aggregate components may also serve as binders (e.g., in place of gelling agents such as corn starch).

[0091] As used herein, the term "binding agent" generally refers to any combination of starting materials that, when combined and reacted, produce a binder through a biological mechanism. For example, a binding agent in a urea hydrolysis-based biobinding system may comprise urea (or another suitable nitrogen source that can or may not be converted in situ to urea, for example, by urea-producing microorganisms, as described in U.S. Patent No. 11,518,687, the contents of which are incorporated herein by reference in their entirety), a soluble calcium source (e.g., calcium chloride, calcium acetate, calcium phosphate, calcium sulfate, calcium lactate, calcium nitrate, etc.). Binding agents may also include enzymes (or organisms containing or expressing enzymes) that can induce the enzymatic formation of biocement (e.g., calcium carbonate), which binds adjacent aggregate particles together. Binding agents may also include nutrients that promote urease activity (which varies depending on whether a pure enzyme or urease-producing cells are used), as well as urease that forms and precipitates calcium carbonate biocement. In calcium carbonate-based bio-sintering bio-binding systems (e.g., including bio-binding systems with features as described in International Application No. PCT / US2020 / 018646, published August 20, 2020, the contents of which are incorporated herein by reference in their entirety), examples of bio-binding agents may include calcium carbonate, for example, in combination with other binding agents (e.g., enzymes, organisms, substrates, nutrients, etc.), which promote enzymatic acid production, such as acid-producing enzymes and their substrates (e.g., sugars), thereby generating acid (i.e., a decrease in pH) to dissolve the calcium carbonate. The bio-binding agents in such systems may also include a second group of nutrients and a second enzyme, which together promote an increase in pH, causing the calcium carbonate to redeposit to form biocement.

[0092] As used herein, in the presence of enzymes or organisms, the term "produce, production, and producing" in relation to calcium carbonate refers to a biological reaction, achieved by enzymes or organisms, that produces calcium carbonate from starting materials (e.g., calcium ions, carbonate ions, or other possible chemical entities). For example, an enzyme that produces carbonate or calcium ions can be called a calcium carbonate-producing enzyme. An enzyme that causes a pH change to precipitate calcium carbonate can also be called a calcium carbonate-producing enzyme.

[0093] As used herein, the term "frame" refers to any structure into which aggregate can be added and which imposes shape on the aggregate. A frame may contain a template. In some cases, a frame includes a mold (e.g., a casting, mold, mold shell, or container) into which the aggregate is inserted. A frame may include one or more inlets and / or one or more outlets. One or more inlets and / or one or more outlets allow fluid and airflow to interact with the aggregate particles within the frame. Outlets in a frame may be fully open surfaces (e.g., open at the top) or holes within the frame that allow fluid or gas to flow out of the frame.

[0094] In some cases, support structures are used to shape the aggregate particles contained within the support structure. The support structure may completely enclose the aggregate particles or partially enclose aggregate particles supported by the support structure. In one example, the support structure is an open-top container. In another example, the support structure is a mold or a rigid mold including holes.

[0095] As used herein, the term microbial-induced calcium carbonate precipitation (MICP) (also known as microbial-induced calcite precipitation) generally refers to the production of calcium carbonate using at least one enzyme or organism. At least one enzyme or organism may form calcium or carbonate ions, or may alter the pH of the environment to precipitate calcium carbonate. In the methods described herein, MICP may also produce carbonates of other metals, which may or may not be incorporated into the bridging calcium carbonate.

[0096] The building materials described herein can take many different forms and shapes. Exemplary building materials, such as units having a top surface, four vertical sides, and a bottom surface (e.g., bricks, tiles, or paving stones), can be used to illustrate several features of the disclosed embodiments. However, the building materials are not limited to cubes. In one instance, the building material may comprise tiles, such as circular tiles having a top surface, vertical circular sides, and a bottom surface. In another instance, a unit may be formed (e.g., pressed) in a mold or template to have one or more curved surfaces, edges, or vertices.

[0097] As used in this article, the unit "g / cc" usually refers to grams per cubic centimeter (g / cm³).3 ), is a unit of density. The percentage of voids within a portion of a building material can be correlated with the average porosity of that portion of the building material.

[0098] Aggregate materials may include rock (e.g., fine aggregate), sand, glass, wood, paper, metal, plastic, polymer, mineral, manufacturing or processing waste (e.g., ash, carbon, or wood residue), any of which may be used crushed or used whole or in combination of both.

[0099] Aggregate materials can include organic or inorganic materials, such as sand, rock, glass (e.g., Poraver), wood, paper, metal, plastic, polymer, mineral, recycled materials, or combinations thereof. Aggregate particles can include beads, fine particles, rods, strands, fibers (e.g., glass fiber, basalt fiber, jute fiber, polymer (e.g., polyethylene or polypropylene) fibers), flakes, crystals, crushed or pulverized materials, or combinations thereof. Building materials can include bricks, pavers, bricks, slabs, tiles, cladding, cinders, micro-bricks, besser bricks, clinker bricks or aerated concrete blocks, countertops or tabletops, design structures, blocks, solid brick structures, piers, foundations, beams, walls, slabs, or combinations thereof.

[0100] Building materials This document provides, in various embodiments, a building material produced by any of the methods, reusable frames, or systems described herein.

[0101] Building materials can also take many different forms and shapes. In some embodiments, the form and / or shape of the building material can be generated by any suitable mold cavity within the framework for producing the building material. In some embodiments, the mold cavity can be brick-shaped. Thus, the building material can be a unit or brick having a top surface, four vertical sides, and a bottom surface. However, building materials are not limited to the form of bricks. For example, another exemplary building material can be a circular tile having a top surface, vertical circular sides, and a bottom surface.

[0102] In some embodiments, the building materials include paving bricks. In some embodiments, the building materials include multiple types of paving bricks. In some embodiments, the building materials include L-shaped walls. In some embodiments, the building materials include wall panels. In some embodiments, the building materials include modular wall panels. In some embodiments, the building materials include New Jersey-style fencing. In some embodiments, the building materials include posts.

[0103] In some embodiments, any building material described herein includes any suitable concrete building material. In specific embodiments, the concrete building material includes any suitable bio-concrete building material. In some embodiments, the building material includes any suitable precast concrete building material. In some embodiments, the building material includes any suitable precast bio-concrete building material.

[0104] In some embodiments, any building material described herein has a compressive strength of at least about 3000 psi (e.g., at least 4000 psi or at least 6000 psi), and / or remains undamaged after 25 cycles of the EN 14617-5 freeze-thaw test. In some embodiments, any building material described herein has a compressive strength of at least about 3000 psi (e.g., at least 4000 psi or at least 6000 psi), and remains undamaged after 25 cycles of the EN 14617-5 freeze-thaw test. In some embodiments, any building material described herein has a compressive strength of at least about 3000 psi (e.g., at least 4000 psi or at least 6000 psi), or remains undamaged after 25 cycles of the EN 14617-5 freeze-thaw test. In some embodiments, any building material described herein has a compressive strength of at least about 3000 psi (e.g., at least 4000 psi or at least 6000 psi). In some embodiments, any building material described herein remains undamaged after 25 cycles of a freeze-thaw test according to EN 14617-5.

[0105] In some embodiments, any building material described herein has a compressive strength of at least about 3,000 psi (e.g., at least 4,000 psi or at least 6,000 psi). In some embodiments, any building material described herein has a compressive strength of at least about 4,000 psi. In some embodiments, any building material described herein has a compressive strength of at least about 6,000 psi. In some embodiments, any building material described herein has a compressive strength of at least about 8,000 psi. In some embodiments, the bio-concrete building material produced by the methods or systems described herein has a compressive strength of from about 900 psi to about 12,000 psi. In some implementations, the bio-concrete building material has a strength of approximately 900 psi to approximately 1,000 psi, approximately 900 psi to approximately 1,100 psi, approximately 900 psi to approximately 1,200 psi, approximately 900 psi to approximately 1,300 psi, approximately 900 psi to approximately 1,400 psi, approximately 900 psi to approximately 1,600 psi, approximately 900 psi to approximately 1,800 psi, approximately 900 psi to approximately 2,000 psi, approximately 900 psi to approximately 2,500 psi, approximately 900 psi to approximately 3,000 psi, approximately 900 psi to approximately 3,500 psi, approximately 1,000 psi to approximately 1,100 psi, approximately 1,000 psi to approximately 1,200 psi, approximately 1,000 psi to approximately 1,300 psi, and approximately 1,000 psi to approximately 1,400 psi. psi, approximately 1,000 psi to approximately 1,600 psi, approximately 1,000 psi to approximately 1,800 psi, approximately 1,000 psi to approximately 2,000 psi, approximately 1,000 psi to approximately 2,500 psi, approximately 1,000 psi to approximately 3,000 psi, approximately 1,000 psi to approximately 3,500 psi, approximately 1,800 psi to approximately 2,000 psi, approximately 1,800 psi to approximately 2,500 psi, approximately 1,800 psi to approximately 3,000 psi, approximately 1,800 psi to approximately 3,500 psi, approximately 2,000 psi to approximately 2,500 psi, approximately 2,000 psi to approximately 3,000 psi, approximately 2,500 psi to approximately 3,000 psi psi, approximately 2,500 psi to approximately 3,500 psi or approximately 3,000 psi to approximately 3,500 psi, approximately 1,100 psi to approximately 4,200 psi, approximately 2,100 psi to approximately 4,300 psi, approximately 2,100 psi to approximately 5,400 psi, approximately 2,100 psi to approximately 5,600 psi, approximately 2,100 psi to approximately 4,800 psi, approximately 2,100 psi to approximately 8,000 psi, approximately 1,100 psi to approximately 7,500 psi, approximately 4,100 psi to approximately 10,000 psi, approximately 5,100 psi to approximately 11,500 psi, approximately 6,200 psi to approximately 7,300 psi, approximately 5,200 psi to approximately 9,400 psi, approximately 6,200 psi to approximately 9,600 psi, approximately 5,200 psi to approximately 11,800 psi, approximately 1,200 psi to approximately 10,000 psi, approximately 2,000 psi to approximately 10,000 psi, approximately 3,000 psi to approximately 10,000 psi, approximately 4,000 psi to approximately 10,000 psi The compressive strengths are approximately 1,000 psi to approximately 10,000 psi, approximately 6,000 psi to approximately 10,000 psi, approximately 7,000 psi to approximately 10,000 psi, approximately 8,000 psi to approximately 10,000 psi, approximately 9,000 psi to approximately 10,000 psi, or approximately 10,200 psi to approximately 12,000 psi. In some embodiments, the bio-concrete building material has compressive strengths of approximately 1,000 psi, approximately 2,000 psi, approximately 3,000 psi, approximately 4,000 psi, approximately 5,000 psi, approximately 6,000 psi, approximately 7,000 psi, approximately 8,000 psi, approximately 9,000 psi, approximately 10,000 psi, approximately 11,000 psi, or approximately 12,000 psi. In some implementations, the bio-concrete building material has a compressive strength of at least 900 psi, 1,000 psi, 2,000 psi, 3,000 psi, 4,000 psi, 5,000 psi, 6,000 psi, 7,000 psi, 8,000 psi, 9,000 psi, 10,000 psi, 11,000 psi, or 12,000 psi.

[0106] In some embodiments, any building material described herein (e.g., building material manufactured using any of the methods or systems described herein) has a flexural strength of 1 to 20 MPa (e.g., 1 to 5 MPa, 2 to 6 MPa, 2 to 12 MPa, 3 to 9 MPa, 4 to 8 MPa, 3 to 10 MPa, 5 to 15 MPa, 3 to 11 MPa, 4 to 12 MPa, 5 to 10 MPa, 8 to 15 MPa, 9 to 18 MPa, 10 to 20 MPa, 5 to 20 MPa, 12 to 20 MPa, or 15 to 20 MPa). In some embodiments, any building material described herein (e.g., building material manufactured using any of the methods or systems described herein) has a flexural strength of at least 1 MPa, at least 2 MPa, at least 3 MPa, at least 4 MPa, 5 MPa, at least 6 MPa, at least 7 MPa, at least 8 MPa, at least 9 MPa, at least 10 MPa, at least 11 MPa, at least 12 MPa, at least 13 MPa, at least 14 MPa. 15 MPa, at least 16 MPa, at least 17 MPa, at least 18 MPa, at least 19 MPa, or at least 20 MPa. In some embodiments, any building material described herein (e.g., building material manufactured using any of the methods or systems described herein) has a flexural strength of about 1 MPa, about 2 MPa, about 3 MPa, about 4 MPa, 5 MPa, about 6 MPa, about 7 MPa, about 8 MPa, about 9 MPa, about 10 MPa, about 11 MPa, about 12 MPa, about 13 MPa, about 14 MPa, 15 MPa, about 16 MPa, about 17 MPa, about 18 MPa, about 19 MPa, or about 20 MPa.

[0107] In some embodiments, any building material described herein remains undamaged after 5 cycles of the EN 14617-5 freeze-thaw test. In some embodiments, any building material described herein remains undamaged after 10 cycles of the EN 14617-5 freeze-thaw test. In some embodiments, any building material described herein remains undamaged after 25 cycles of the EN 14617-5 freeze-thaw test. In some embodiments, any building material described herein remains undamaged after 30 cycles of the EN 14617-5 freeze-thaw test.

[0108] In some embodiments, any building material described herein (e.g., building material manufactured using any of the methods or systems described herein) has an finished density of about 2 g / cc to about 3 g / cc, such as about 1.8 g / cc to about 1.9 g / cc, about 1.9 g / cc to about 2.0 g / cc, about 2.0 g / cc to about 2.1 g / cc, about 2.1 g / cc to about 2.2 g / cc, about 2.2 g / cc to about 2.3 g / cc, about 2.3 g / cc to about 2.4 g / cc, about 2.4 g / cc to about 2.5 g / cc, about 2.5 g / cc to about 2.6 g / cc, about 2.6 g / cc to about 2.7 g / cc, about 2.8 g / cc to about 2.9 g / cc, about 2.9 g / cc to about 3.0 g / cc, about 3.0 g / cc to about 3.1 g / cc, or about 3.1 g / cc to about 3.2 g / cc. In some embodiments, the average finished product density is about 2.0 g / cc to about 2.1 g / cc. In some embodiments, the average finished product density is about 2.1 g / cc to about 2.3 g / cc. In some embodiments, the average finished product density is about 2.2 g / cc to about 2.4 g / cc. In some embodiments, the average finished product density is about 2.0 g / cc to about 2.5 g / cc. In some embodiments, the average finished product density is about 2.5 g / cc to about 3 g / cc. In some embodiments, the average finished product density is about 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, or 3.3 g / cc. In some implementations, the average finished product density is greater than 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2 or 3.3 g / cc.

[0109] Methods of producing building materials This document provides a method for producing any suitable building material described herein, in various implementation schemes.

[0110] In some embodiments, any method provided herein includes: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; allowing a first fluid containing a binding agent to flow through the frame-like plurality of aggregate particles, wherein the fluid is introduced into the frame in one direction such that the flow direction is opposite to gravity; and reacting the binding agent with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming a building material.

[0111] In some embodiments, any method provided herein includes: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; allowing a first fluid containing a binder to flow through the frame-like plurality of aggregate particles at a pressure above atmospheric pressure; and reacting the binder with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming a building material.

[0112] In some embodiments, any method provided herein includes adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; substantially venting air from the void spaces between the frame-like plurality of aggregate particles; allowing a first fluid containing a binding agent to flow through the frame-like plurality of aggregate particles; and reacting the binding agent with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming a building material.

[0113] In some embodiments, any method provided herein includes compacting a plurality of aggregate particles in a frame to reduce the volume of void space between adjacent particles of the plurality of aggregate particles; allowing a first fluid containing a cementing agent to flow through the void space of the plurality of aggregate particles; and reacting the cementing agent with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming a building material.

[0114] In some embodiments, any method provided herein includes adding a plurality of any suitable aggregate particles described herein into any suitable framework described herein. In some embodiments, adding a plurality of aggregate particles into a framework results in the formation of a framework of aggregate particles.

[0115] In some embodiments, any aggregate used in any method, reusable frame, or system provided herein comprises any suitable aggregate. In some embodiments, any suitable aggregate comprises multiple aggregate particles. In specific embodiments, the multiple aggregate particles comprise sand, gravel, a combination of sand and gravel, or any suitable material. In some embodiments, the multiple aggregate particles comprise sand. In some embodiments, the multiple aggregate particles comprise gravel. In some embodiments, the multiple aggregate particles comprise an admixture of sand and gravel. In some embodiments, the multiple aggregate particles consist substantially of an admixture of sand and gravel.

[0116] In a more specific implementation, the sand and gravel blend comprises any volume percentage of sand and gravel suitable for producing building materials.

[0117] In some embodiments, the sand and gravel mixture comprises 1-99% sand and 1-99% gravel by volume. In some embodiments, the sand and gravel mixture comprises 55-75% sand and 25-45% gravel by volume. In some embodiments, the sand and gravel mixture comprises 66% sand and 34% gravel. In some embodiments, the sand and gravel mixture comprises 1% sand and 90% gravel. In some embodiments, the sand and gravel mixture comprises 90% sand and 1% gravel. In some embodiments, the sand and gravel mixture comprises 20% sand and 80% gravel. In some embodiments, the sand and gravel mixture comprises 80% sand and 20% gravel. In some embodiments, the sand and gravel mixture comprises 60% sand and 40% gravel. In some embodiments, the sand and gravel mixture comprises 40% sand and 60% gravel. In some implementations, the sand and gravel mixture comprises 50% sand and 50% gravel.

[0118] In some embodiments, the average particle size of the sand is smaller than the average particle size of the gravel. In some embodiments, the average particle size of the sand is at least 10 times smaller than the average particle size of the gravel (e.g., at least 20 times, 50 times, or 100 times smaller). In some embodiments, the average particle size of the sand is at least 20 times smaller than the average particle size of the gravel. In some embodiments, the average particle size of the sand is at least 50 times smaller than the average particle size of the gravel. In some embodiments, the average particle size of the sand is at least 100 times smaller than the average particle size of the gravel. In some embodiments, the average particle size of the sand is at least 200 times smaller than the average particle size of the gravel. In some embodiments, the average particle size of the sand is at least 500 times smaller than the average particle size of the gravel.

[0119] In some embodiments, the aggregate particles can be in any suitable state suitable for producing the building materials described herein. In some embodiments, the aggregate particles can be wet. In some embodiments, the aggregate particles can be solvated. In some embodiments, the aggregate particles can be solid. In some embodiments, the aggregate particles can be a slurry.

[0120] In some implementations, multiple aggregate particles may be mixed with any suitable binder provided herein before being added to the frame.

[0121] In some cases, the cell concentration of the biological organisms added to the aggregate mixture has grown to at least a specific concentration or at least a specific number of cells before being added to the aggregate mixture. In some embodiments, the cell concentration of the biological organism in the solution added to the aggregate mixture is about 10,000 CFU / mL to about 1,000,000,000,000 CFU / mL, or about 10,000 CFU / mL to about 100,000 CFU / mL, or between 10,000 CFU / mL and 100,000,000 CFU / mL, or between 1,000,000 CFU / mL and 10,000,000 CFU / mL, or between 1,000,000 CFU / mL and 100,000,000 CFU / mL, or between 1,000,000 CFU / mL and 100,000,000 CFU / mL. The concentration of organic cells in the aggregate can be between 1,000,000 CFU / mL and 1,000,000,000 CFU / mL, or between 1,000,000 CFU / mL and 10,000,000,000 CFU / mL, or between 10,000,000 CFU / mL and 1,000,000,000 CFU / mL, or between 100,000,000 CFU / mL and 1,000,000,000 CFU / mL. Prior to feeding the cementing agent, the cell concentration of organic cells in the aggregate can be between approximately 1 × 10⁻⁶. 2 With 1×10 12 Between CFU / gram of aggregate admixture, for example, 1×10 3 With 1×10 10 Between CFU / gram, for example, 1×10 5 With 5×10 9 Between CFU / gram, for example, 1×10 7 With 5×10 9 Between CFU / gram, for example, 1×10 6 With 2×10 9 Between CFU / gram, for example, 5 × 10 6 With 2×10 9 Between CFU / gram, for example, 1×10 8 With 1×10 12 Between CFU / gram, for example, 1×10 9 With 1×10 11 Between CFU / gram, for example, 1×10 10 With 1×10 12 (between CFU / gram).

[0122] In other embodiments, any method provided herein includes adding any suitable reinforcing material (e.g., steel bars, glass fiber reinforced bars, or glass fiber bundles) to the frame. In some embodiments, the reinforcing material comprises steel bars. In some embodiments, the reinforcing material comprises glass fiber reinforced bars. In some embodiments, the reinforcing material comprises glass fiber bundles. In some embodiments, the reinforcing material is added prior to the addition of the plurality of aggregate particles described herein. In some embodiments, the reinforcing material is added simultaneously with the addition of the plurality of aggregate particles.

[0123] In some embodiments, any method provided herein includes settling a plurality of aggregate particles into the mold cavity of the frame in any suitable manner. In some embodiments, settling can be performed in any suitable manner to reduce void volume within the mold. In some embodiments, settling can be performed using any suitable mechanical force. In some embodiments, the plurality of aggregate particles can be pressed to achieve settling. In some embodiments, the plurality of aggregate particles can be vibrated to achieve settling. In some embodiments, the plurality of aggregate particles can be both pressed and vibrated to achieve settling.

[0124] In some embodiments, settling can occur while multiple aggregate particles are dry. In some embodiments, settling can occur while multiple aggregate particles are wet. In other embodiments, settling is carried out at least in part by applying a pressurized solvent (e.g., water) to the particles at any suitable pressure configured to increase the bulk density of the particles.

[0125] In some embodiments, any method provided herein includes flowing a fluid containing a binding agent through a frame of aggregate particles in any suitable manner. In some embodiments, the fluid is introduced into the frame in one direction such that the flow direction is opposite to gravity. In some embodiments, the fluid is introduced into the frame in one direction such that the fluid flows from the bottom, sides, top, or any combination thereof of the frame. In some embodiments, the fluid is introduced into the frame in one direction such that the fluid flows from the bottom of the frame. In some embodiments, the fluid is introduced into the frame in one direction such that the fluid flows from the top of the frame. In some embodiments, the fluid is introduced into the frame in one direction such that the fluid flows from any side of the frame. In some embodiments, the fluid is introduced into the frame in one direction such that the fluid flows from one or more sides of the frame. In some embodiments, the fluid is introduced into the frame in one direction such that the fluid flows from the bottom, top, and sides of the frame. In some embodiments, a method includes flowing more than one fluid. In some embodiments, the fluid comprises a first fluid and a second fluid.

[0126] In some embodiments, a first fluid flows through a plurality of frame-shaped aggregate particles, entering through the lower surface of the frame and exiting through the upper surface of the frame. In some embodiments, the fluid flows through the plurality of aggregate particles at a first pressure at a first time. In some embodiments, the first pressure is greater than atmospheric pressure. In other embodiments, the fluid flows through the plurality of aggregate particles at a second pressure at a second time. In a specific embodiment, the second pressure is greater than the first pressure. In some embodiments, a second fluid containing a binding agent is flowed through the plurality of frame-shaped aggregate particles before, during, or after the reaction as described herein. In some embodiments, a second fluid containing a binding agent is flowed through the plurality of frame-shaped aggregate particles before the reaction. In some embodiments, a second fluid containing a binding agent is flowed through the plurality of frame-shaped aggregate particles during the reaction. In some embodiments, a second fluid containing a binding agent is flowed through the plurality of frame-shaped aggregate particles after the reaction.

[0127] In some embodiments, the fluid (e.g., a first fluid or a second fluid) is recirculated through the frame at any suitable number of cycles. In some embodiments, each cycle of the multiple cycles increases the degree of consolidation of multiple aggregate particles. In some embodiments, the fluid (e.g., a first fluid or a second fluid) is recirculated through the frame multiple times. In some embodiments, the fluid that is recirculated for a total of at least 3 cycles (e.g., at least 5 cycles or at least 10 cycles) flows through the frame. In some embodiments, the fluid that is recirculated for a total of at least 5 cycles flows through the frame. In some embodiments, the fluid that is recirculated for a total of at least 10 cycles flows through the frame. In some embodiments, the fluid that is recirculated for a total of at least 20 cycles flows through the frame.

[0128] In some embodiments, the fluid (e.g., a first fluid or a second fluid) comprises any volume suitable for use with any method, system, or rejectable frame as described herein. In some embodiments, the volume of the fluid (e.g., a first fluid or a second fluid) is about 50% to about 500% (e.g., about 75% to about 150%) of the frame volume. In some embodiments, the volume of the fluid (e.g., a first fluid or a second fluid) is about 75% to about 150% of the frame volume.

[0129] In some embodiments, the pressure applied to any fluid flow to the frame-like plurality of particles is any suitable pressure. In some embodiments, the pressure is at least about 1 psi (e.g., at least about 5, 10, 20, 50, or 100 psi). In some embodiments, the pressure is at least about 5 psi. In some embodiments, the pressure is at least about 10 psi. In some embodiments, the pressure is at least about 20 psi. In some embodiments, the pressure is at least about 50 psi. In some embodiments, the pressure is at least about 100 psi. In some embodiments, the pressure is at least about 250 psi.

[0130] In some embodiments, any cementing agent described herein comprises any cementing agent suitable for the production of building materials. In some embodiments, the cementing agent comprises a biological organism (or its spores), an enzyme, urea (and / or its derivatives), a calcium salt (e.g., CaCl2), a nutrient, or a combination of two or more of these substances. In some embodiments, the cementing agent comprises any suitable biological organism (or its spores). In a specific embodiment, the biological organism is an organism (or its spores) that produces urease. The microorganism that produces urease may originate from the archaea domain (e.g., halophilic archaea), the bacteria domain, or the eukaryotic domain (e.g., fungi (e.g., yeasts (e.g., genus *saccharomyces*) or filamentous fungi (e.g., genus *Aspergillus*)), and some algae (e.g., *Thraustochytrids*)). Urease-producing bacteria include organisms from the following phyla: Pseudmonadota (e.g., α-Proteobacteria, β-Proteobacteria, γ-Proteobacteria (e.g., Enterobacteriaceae, Enterobacteriales, Proteobacteriae (species related to Proteus mirabilis and Proteus vulgaris)); or Alternating Monotrophs (e.g., Shewanellaceae, Shewanellae (species such as Shewanella putrefaciens, Shewanella oneidensis, and Shewanella sediminis), δ-Proteobacteria), Firmicutes, and Campylobacterota). (e.g., Campylobacteria, Campylobacterales, Helicobacteraceae, Helicobacter genus, organisms associated with Helicobacter pylori), Myxococcota (e.g., Myxococcota, Myxococales, Myxococaceae, species such as Myxococcus Xanthus) or Actinobacteria (e.g., considered as such).Firmicutes, which produce urease, include organisms such as: Bacillus family (e.g., *Alkalibacillus*, *Alkalicoccus*, *Alkalihalobacillus*, *Bacillus*, *Halalkalibacillus*, *Halobacillus*, *Halolactibacillus*, *Lysinibacillus*, *N-sodium-rich Bacillus*). *Bacillus atribacillus*, *Natronobacillus*, *Priestia*, *Pseudobacillus*, *Pseudogracilibacillus*, *Pseudoneobacillus*, *Psychrobacillus*, and *Thermalkalibacillus*; for example, *Lysinibacillus*. Bacillus species include *Bacillus sphaericus*, *Bacillus subtilis*, *Bacillus megaterium*, etc., or species such as those in the Caryophanaceae family (e.g., *Sporosarcina* (e.g., *Sporosarcina ureae*, etc.)), *Bhargavaea* (e.g., *Bhargavaea beijingensis*), or *Paenibacillaceae* (e.g., *Paenibacillus*). In a more specific embodiment, the urease-producing organism is *Sporosarcina ureae*. In some embodiments, the cementing agent contains any suitable enzyme. In some embodiments, the cementing agent contains urea (and / or its derivatives). In some embodiments, the enzyme is urease. In some embodiments, the cementing agent contains any suitable enzyme. In some embodiments, the cementing agent contains a calcium salt (e.g., CaCl2). In some embodiments, the cementing agent contains nutrients that promote enzyme activation or expression. In some embodiments, the cementing agent contains nutrients for feeding bacteria. In some embodiments, the cementing agent includes acid-producing enzymes or acid-producing microorganisms (e.g., microorganisms that produce one or more acid-producing enzymes).Acid-producing microorganisms may come from the Archaea domain (e.g., halophilic archaea), Bacteria domain, or Eukaryotic domain (e.g., fungi (e.g., yeasts (e.g., Yeast) or filamentous fungi (e.g., Aspergillus)), as well as some algae (e.g., Chrysochrysis)). The acid-producing microorganisms may be selected from the group consisting of: *Variovorax*, *Klebsiella*, *Pseudomonas*, *Bacillus*, *Exiguobacterium*, *Microbacterium*, *Curtobacterium*, *Rathayibacter*, *Streptomyces*, *Raoultella*, *B. pumilus*, *B. safanensis*, *B. simplex*, *B. licheniformis*, *B. spherical lysine-producing*, and combinations thereof. In some embodiments, the cementing agent comprises one or more carbonic anhydrases, or one or more microorganisms expressing carbonic anhydrases. In some embodiments, the carbonic anhydrase-producing microorganism may be the same organism as the urease-producing microorganism or the acid-producing microorganism. In some embodiments, the microorganisms that produce carbonic anhydrase are different from those that produce urease. In one embodiment, the feed solution (e.g., a liquid solution containing dissolved or dispersed binding agents) or aggregate mixture of the system or method described herein may include carbonic anhydrase (or carbonic anhydrase-producing microorganisms, such as archaea, bacteria (e.g., thermophilic bacteria), or eukaryotes (e.g., fungi (e.g., yeasts (e.g., *Saccharomyces* or filamentous fungi (e.g., *Aspergillus*)), and some algae), and gaseous carbon dioxide, such as captured carbon dioxide, may be further introduced into the feed solution or frame. In some embodiments, the cementation in the aggregate... The reagents include enzymes or organisms, and the binding agent in the fluid (e.g., feed solution) supplied to the aggregate comprises a calcium ion source (e.g., calcium chloride). In some embodiments, the binding agent in the aggregate comprises enzymes or organisms and urea, and the binding agent in the fluid (e.g., feed solution) supplied to the aggregate comprises a calcium ion source (e.g., calcium chloride) and urea. In some embodiments, the binding agent in the aggregate comprises enzymes or organisms and urea, and the binding agent in the fluid (e.g., feed solution) supplied to the aggregate comprises a calcium ion source (e.g., calcium chloride) and urea.

[0131] In some embodiments, one or more fluids supplied to the aggregate within the frame include microorganisms or enzymes. In some embodiments, one or more fluids supplied to the aggregate within the frame do not include microorganisms or enzymes (or only include trace amounts, such as less than 0.1 g per liter of enzyme or microorganism, such as less than 1000 CFU per liter of microorganism, such as less than 100 CFU per liter of microorganism, such as less than 10 CFU per liter of microorganism, such as less than 1 CFU per liter of microorganism, such as having a specific urease activity or a specific carbonic anhydrase activity that is statistically indistinguishable from the water source used in the process).

[0132] In some embodiments, the cementing agent contained in the first fluid comprises any biological organism (e.g., microorganisms) (or spores thereof) and / or any enzyme described herein. In some embodiments, the cementing agent contained in the first fluid comprises any biological organism (or spores thereof) and any enzyme described herein. In some embodiments, the cementing agent contained in the first fluid comprises any biological organism (or spores thereof) or any enzyme described herein. In some embodiments, the cementing agent contained in the first fluid comprises any biological organism (or spores thereof). In some embodiments, the cementing agent contained in the first fluid comprises any enzyme described herein. In some embodiments, the cementing agent contained in the first fluid comprises any suitable nutrient. In some embodiments, the cementing agent contained in the first fluid comprises any suitable nutrient that promotes the activity of the biological organism and / or the enzyme. In alternative embodiments, the cementing agent contained in the first fluid does not contain any nutrient that promotes the activity of the biological organism and / or the enzyme.

[0133] In some embodiments, the cementing agent contained in the second fluid contains nutrients that promote the activity of biological organisms and / or enzymes.

[0134] In some embodiments, any method provided herein includes, prior to the reaction, substantially expelling air from the void spaces between the multiple aggregate particles in any suitable manner described herein, such as using pressure or mechanical force. In some embodiments, air expulsion may be carried out in the same manner as settling described herein.

[0135] In some embodiments, any method provided herein includes compacting multiple aggregate particles within a frame in any suitable manner. In some embodiments, any method provided herein includes compacting multiple aggregate particles within a frame in any suitable manner described herein, such as using pressure or mechanical force, to reduce the volume of void space between adjacent particles of the multiple aggregate particles. In some embodiments, compaction may be performed in the same manner as settlement described herein.

[0136] In some embodiments, any method provided herein includes reacting a cementing agent with a biological organism and / or enzyme contained within a fluid or a plurality of framework aggregate particles as described herein. In some embodiments, a method includes reacting a cementing agent with a biological organism and / or enzyme contained within a fluid or a plurality of framework aggregate particles for a reaction time sufficient to solidify the plurality of framework aggregate particles. In some embodiments, a method includes reacting a cementing agent with a biological organism and / or enzyme contained within a fluid or a plurality of framework aggregate particles for a reaction time sufficient to solidify the plurality of framework aggregate particles, thereby forming a building material. In some embodiments, the reaction binds adjacent particles of the plurality of particles together via calcium carbonate bridges, thereby forming a building material.

[0137] Reusable frames for producing precast bioconcrete building materials This document provides, in some embodiments, a reusable frame for producing precast bioconcrete building materials as described herein.

[0138] In some embodiments, a reusable frame for producing precast bioconcrete building materials includes: a plurality of panels configured to: (i) be temporarily fixed together during curing of the precast bioconcrete building materials to form a fluid connection system, and (ii) be released to allow the precast building materials to be demolded from a cavity formed when the plurality of panels are fixed together; a binder inlet; a binder outlet; wherein the volume of the cavity formed when the panels are fixed together is at least 50 L (e.g., at least 100 L or at least 1000 L), the binder inlet is located on at least one of the plurality of panels and is configured to be fluidly connected to the cavity when the plurality of panels are temporarily fixed, and the binder outlet is located on at least one of the plurality of panels and is configured to be fluidly connected to the cavity when the plurality of panels are temporarily fixed.

[0139] In some embodiments, the reusable frame provided herein includes any suitable panels. In some embodiments, the reusable frame includes multiple panels. In some embodiments, the multiple panels are configured to be temporarily fixed together to form a fluid-bonded system as described herein. In specific embodiments, the multiple panels are configured to be temporarily fixed together during the curing of the building material as described herein to form a fluid-bonded system. In specific embodiments, the multiple panels are configured to be temporarily fixed together during the curing of the precast bioconcrete building material to form a fluid-bonded system. In some embodiments, the multiple panels are configured to be released. In specific embodiments, release allows any building material to be demolded from the mold cavity formed when the multiple panels are fixed together. In some embodiments, the multiple panels are configured to: (i) be temporarily fixed together during the curing of the precast bioconcrete building material to form a fluid-bonded system, and (ii) be released to allow the precast building material to be demolded from the mold cavity formed when the multiple panels are fixed together.

[0140] In some embodiments, the plurality of panels described herein include at least one patterned panel, the pattern being configured to alter the aesthetic appearance of one or more surfaces of any suitable building material. In some embodiments, the plurality of panels described herein include at least one patterned panel, the pattern being configured to alter the aesthetic appearance of one or more surfaces of the prefabricated building material. In some embodiments, when the plurality of panels described herein are assembled into a frame, their inner surfaces include voids (e.g., convex surfaces, cavities, curved voids, grooves, recesses). In some embodiments, when the plurality of panels described herein are assembled into a frame, their outer surfaces include voids (e.g., convex surfaces, cavities, curved voids, grooves, hollows). In some embodiments, the outlet is located at the apex of the cavity, the upper part of the cavity, or the portion of the cavity furthest from the frame entrance.

[0141] In some embodiments, the multiple panels described herein are configured modularly, which allows for the manufacture of various types or quantities of any suitable building material using the same reusable frame. In some embodiments, the multiple panels are configured modularly, which allows for the manufacture of various types or quantities of precast bioconcrete material using the same reusable frame. In some embodiments, the multiple panels include entrance and exit panels, which are assembled with one or more additional panels such that the entrance and exit panels are located at opposite ends of the longest dimension of the assembled frame.

[0142] In some embodiments, the precast bioconcrete material produced by any framework provided herein comprises various paving bricks, L-shaped walls, modular wall panels, and / or New Jersey-style guardrails. In some embodiments, the precast bioconcrete material comprises paving bricks. In some embodiments, the precast bioconcrete material comprises various paving bricks. In some embodiments, the precast bioconcrete material comprises L-shaped walls. In some embodiments, the precast bioconcrete material comprises wall panels. In some embodiments, the precast bioconcrete material comprises modular wall panels. In some embodiments, the precast bioconcrete material comprises New Jersey-style guardrails. In some embodiments, the precast bioconcrete material comprises columns.

[0143] In some embodiments, the reusable frame provided herein includes any suitable bonding agent inlet. In some embodiments, the reusable frame provided herein includes any suitable bonding agent outlet. In some embodiments, the reusable frame provided herein includes both a suitable bonding agent inlet and outlet.

[0144] In some embodiments, the binder inlet is located on at least one of the plurality of panels as described herein and is configured to be fluidly connected to the mold cavity when the plurality of panels are temporarily fixed, as described herein. In some embodiments, the binder inlet is configured to be located on a panel lower than the binder outlet when the plurality of panels are temporarily fixed. In some embodiments, the binder inlet is configured to allow pressurization of fluid within the mold cavity of the reusable frame.

[0145] In some embodiments, the adhesive outlet is located on at least one of a plurality of panels as described herein and is configured to be fluidly connected to the mold cavity when the plurality of panels are temporarily fixed, as described herein. In some embodiments, the adhesive outlet is configured to allow pressurization of fluid within the mold cavity of a reusable frame.

[0146] In some embodiments, the binder inlet and / or binder outlet are configured to allow pressurization of fluid within the mold cavity of the reusable frame. In some embodiments, the binder inlet and binder outlet are configured to allow pressurization of fluid within the mold cavity of the reusable frame. In some embodiments, the binder inlet or binder outlet is configured to allow pressurization of fluid within the mold cavity of the reusable frame.

[0147] In some embodiments, the reusable frame provided herein includes any suitable vent. In some embodiments, the vent is configured to allow air to escape from the mold cavity. In some embodiments, the reusable frame provided herein includes any suitable number of vents. In some embodiments, the reusable frame provided herein includes one vent. In some embodiments, the reusable frame provided herein includes more than one vent. In some embodiments, the vent includes a shut-off valve that allows air to pass through but prevents liquids (e.g., water) from passing through, for example, a valve including a buoyancy element.

[0148] In some embodiments, within the reusable frame provided herein, the volume of the cavity formed when the panels are fixed together is at least 50 L (e.g., at least 100 L or at least 1000 L). In some embodiments, the volume of the cavity formed when the panels are fixed together is at least 100 L. In some embodiments, the volume of the cavity formed when the panels are fixed together is at least 500 L. In some embodiments, the volume of the cavity formed when the panels are fixed together is at least 1000 L. In some embodiments, the volume of the cavity formed when the panels are fixed together is at least 2000 L.

[0149] Systems for producing pre-concrete building materials This article provides, in some embodiments, a system for producing precast bioconcrete building materials as described herein.

[0150] In some embodiments, the system provided herein includes any reusable frame described herein, any suitable fluid manifold, and any suitable pump. In some embodiments, the system provided herein includes any reusable frame described herein. In some embodiments, the system provided herein includes any suitable fluid manifold. In some embodiments, the system provided herein includes any suitable pump. In some embodiments, the pump is fluidly connected to the fluid manifold, the cementing reagent inlet, and / or the cementing reagent outlet of the reusable frame. In some embodiments, the pump is fluidly connected to the fluid manifold. In some embodiments, the pump is fluidly connected to the cementing reagent inlet described herein. In some embodiments, the pump is fluidly connected to the cementing reagent outlet described herein. In some embodiments, the pump is fluidly connected to the fluid manifold, the cementing reagent inlet, or the cementing reagent outlet of the reusable frame. In some embodiments, the pump is fluidly connected to the fluid manifold, the cementing reagent inlet, and the cementing reagent outlet of the reusable frame.

[0151] In other embodiments, the system provided herein also includes any suitable recirculation tank configured to recirculate any fluid described herein through any reusable frame described herein.

[0152] In other embodiments, the system provided herein also includes any suitable reagent reservoir configured to provide the fresh bonding agent described herein to the recycling reservoir described herein, to the mold cavity of the reusable frame described herein, or both. In some embodiments, the system provided herein includes any suitable reagent reservoir configured to provide the fresh bonding agent described herein to the recycling reservoir described herein. In some embodiments, the system provided herein includes any suitable reagent reservoir configured to provide the fresh bonding agent described herein to the mold cavity of the reusable frame described herein. In some embodiments, the system provided herein includes any suitable reagent reservoir configured to provide the fresh bonding agent described herein to either the recycling reservoir described herein or the mold cavity of the reusable frame described herein. In some embodiments, the system provided herein includes any suitable reagent reservoir configured to provide the fresh bonding agent described herein to both the recycling reservoir and the mold cavity of the reusable frame described herein.

[0153] In other embodiments, the system provided herein also includes any suitable storage tank. In some embodiments, the storage tank is configured to accumulate waste liquid and / or fluid that has exhausted its binding agent. In some embodiments, the storage tank is configured to accumulate waste liquid and fluid that has exhausted its binding agent. In some embodiments, the storage tank is configured to accumulate waste liquid or fluid that has exhausted its binding agent. In some embodiments, the storage tank is configured to accumulate waste liquid. In some embodiments, the storage tank is configured to accumulate fluid that has exhausted its binding agent as described herein.

[0154] In some implementations, the system provided herein can perform any of the methods provided herein.

[0155] Example This application can be better understood by referring to the following non-limiting embodiments, which are provided as exemplary implementations of this application. The following embodiments are presented to illustrate the implementation more fully; however, they should not in any way be construed as limiting the broad scope of this application.

[0156] Example 1 - Paving bricks manufactured using dry aggregate mixture process A 7-unit paving brick frame was used as a mold to fill the cavities of each paving brick with aggregate. Figure 1A Activated Danish aggregate S66T34 was used as the aggregate admixture. Aggregate was present on all six sides of the paving brick frame. Figure 1B Using 60 liters of dry aggregate, seven paving bricks were made, each weighing 8.39 liters. These seven paving bricks include paving brick 102. After the dry aggregate was compacted into the mold, the top portion was immediately and securely attached, and the entire mold was lifted. No curing time was set, allowing the aggregate to dry before feeding.

[0157] Figure 2 The feeding scheme was demonstrated. Urea, CaCl2, and nutrients were fed to each paving brick. Specifically, the feeding process used a single 100-liter container equipped with a water collection pump (e.g., a recirculation pump), located directly below the mold or paving brick frame 104. A flexible conduit connected the water collection pump to the bottom portion of the mold's gas collection chamber, while another flexible conduit connected to the top gas collection chamber, to recirculate the fluid back into the 100-liter container. A bath containing 50 liters of CaCl2 / urea feed solution was introduced into the 100-liter container. The water collection pump then propelled the fluid from the bottom gas collection chamber through the mold to the top gas collection chamber. This recirculation process lasted 3 hours and 50 minutes, allowing 10 minutes to empty the mold and replace the bath with 50 liters of fresh solution.

[0158] The initial plan was to conduct a total of 12 such baths. However, after the ninth bath, the water pump malfunctioned, and due to a lack of monitoring, the problem went undetected for several more baths. This ultimately led to the premature termination of the experiment. Although all 12 baths were prepared and placed in 100-liter containers, it is suspected that the last three baths never entered the mold. A total of 450 liters of fluid were used (600 liters for the 12 baths). The mold was disassembled immediately after the twelfth bath without any rinsing or additional curing time. Unfortunately, during disassembly, several paving bricks cracked, possibly due to the lack of paint on the steel mold and aggregate adhering to the steel plate. Within a week, these paving bricks were cut into different samples for testing.

[0159] Performance testing Figure 3A The location of the sample is shown. The solid outline corresponds to a 16'' (400 mm) square paving brick. Each dashed square within the paving brick corresponds to a 2'' (50 mm) cube, while a complete solid square corresponds to a 400 mm × 400 mm × 50 mm paving brick.

[0160] Compressive strength and EOR density were tested in the dashed square samples on the sides and bottom. Figure 3A ), the result is Figure 3BThe compressive strength of the samples ranged from 2,200 PSI to 9,200 PSI. The EOR density of the samples ranged from 1.89 g / cc to 2.28 g / cc.

[0161] Bending strength tests were conducted on FW38 and FW45. Figure 3A ), the result is Figure 3C As shown in the image. The bending test has been completed. The average bending strength is 8.9 MPa, which represents the highest grade mark for paving stones.

[0162] Preliminary absorption tests have also been conducted, indicating an absorption rate of 3.85%. Furthermore, the global warming potential (GWP) ranges from 15.0 kg CO2eq / m2 to 6.0 kg CO2eq / m2 at 2 cm equivalent. 2 These results demonstrate that microbial-induced calcite precipitation (MICP) can produce paving bricks that meet specified standards while maintaining low GWP.

[0163] Example 2 – Process for manufacturing small precast components using dry aggregate mixtures The system, which uses frames, cell culture, and raw material baths, can produce 100 square feet of BS EN 1339:200324''×24''×3'' flag-shaped paving bricks, or any other bio-concrete products with a total volume approximately the same as 100 square feet of such paving bricks.

[0164] Figure 4A An example of a frame is shown, the frame being sized to be able to seal between the top and bottom gas chambers of a system, for example, between the top and bottom gas chambers of a panel mold (e.g., a panel mold) with a rectangular outer profile. Figure 4B An exploded view of a paving brick production system is shown. This system can produce multiple paving bricks simultaneously (e.g., seven paving bricks).

[0165] Cell culture can be prepared using the following steps. Before inoculation, thoroughly clean the containers (e.g., buckets or stock tanks), pumps, and related tubing with Alconox and rinse with clean water. A full-load wet test system with clean water was also performed to verify typical aeration and mixing conditions for large-volume culture growth. Add 750 L of clean tap water to the stock tank, with a target final temperature of 33°C. Start the system recirculation pump to begin mixing. All dried components of the cell culture medium, except for the cells on the solid support, are added and mixed via system recirculation. After the dry materials are fully mixed, check the medium temperature. The temperature is expected to drop by approximately 1°C due to urea dissolution. Once the medium temperature is confirmed to be between 31°C and 33°C, add the cells on solid supports to the recirculation stock tank. Culture growth is expected to take 20–24 hours. During growth, the culture temperature should be maintained within the range of 30°C–35°C. After 20–24 hours of growth, check if the cell population has reached sufficient cell density (e.g., by optical density). Inoculate the stock by recirculating the culture from the bottom gas chamber through the stock within the frame.

[0166] After inoculation, the system switches to supplying raw materials to the aggregate. The raw material bath is prepared according to the following protocol: Add 250 L of water to the mixing tank at approximately 30°C. Slowly add urea (5-10 kg) and nutrients to the tank while stirring. Slowly add CaCl2 (10-20 kg) to the mixing tank to maintain the temperature within the correct range. Add water to the mixing tank to a final volume of 400 L, with a target temperature of 30°C.

[0167] The panel mold for producing the aforementioned 100 square feet of paving bricks is expected to require a total of 15 baths per run, with the raw material bath being replaced every 4 hours.

[0168] Example 3 – Process for manufacturing large precast components using wet aggregate mixtures L-shaped wall barrier According to an embodiment of the system and method disclosed herein, an L-shaped wall barrier is produced using a pre-inoculated wet aggregate mixture (S66T34) Skygge blend.

[0169] Mold preparation The L-shaped frame (L-shaped mold 502) ( Figure 5A The mold cavity is pickled and cleaned to ensure a smooth surface free of debris from previous runs. Fabric is added to the grates of the top and bottom air chambers to act as filters and prevent aggregate from being washed away. Foam gaskets and silicone are added to the mold flanges to ensure a watertight seal when clamped. The mold is then bolted together using an impact drill, leaving space in the top air chamber for aggregate filling. Finally, all internal metal surfaces are coated with a non-stick coating.

[0170] filler Evenly fill the mold with the inoculated aggregate, to a depth not exceeding the permissible level of full compaction. Apply pressure to the mold using a filling tool until the aggregate is fully compacted. After removing the filling tool, sand the surface of the compacted aggregate to prevent any visible seams between the compacted aggregate layers. Repeat this process until the mold is full. Before placing the top gasket, place the gasket and filter cloth on the compacted aggregate.

[0171] Feeding Dilute the Pre-Nutrix solution with water to a 10:1 ratio. Allow the solids in the solution to settle, and collect the diluted liquid for feed preparation. Begin preparing the bath using calcium chloride and urea as starting points. Initially, fill the bath with 100 L of water at or below room temperature. Add all feed components to the bath and stir until dissolved. Then add water until reaching 150 L, using appropriately heated water to achieve the target bath temperature of 35°C. Pump the bath liquid into the bottom gas chamber of the mold, and then discharge it from the top gas chamber back into the bath, circulating the feed through the mold to add it to the aggregate. Repeat the feed circulation through the mold until the first bath change. The raw materials change. Repeat the feeding process until it is considered complete.

[0172] Demolding After feeding is complete, empty the bath and mold. Remove the bolts from the mold and carefully separate the mold wall from the bonded structure. Figure 5B The image shows an L-shaped wall barrier 504.

[0173] Similarly, other prefabricated building materials, such as modular wall panels 602 ( Figure 6 ), New Jersey-style guardrail 702 ( Figure 7A ) or column ( Figure 8A Alternatively, the same process can be used, with either dry or wet mixes, and different molds. The produced 1.98 m³ wall panels were tested in several uniform areas, with compressive strengths ranging from 2,459 to 4,715 PSI. The produced 0.6 m³ New Jersey-style fencing was tested in several uniform areas, with compressive strengths ranging from 988 to 2,451 PSI.

[0174] Fiberglass reinforced steel elements can be placed into a mold to increase the unit tensile strength, for example... Figure 7B The steel reinforcement element 712 in the middle. Figure 7B and 8B An example of this glass fiber reinforced steel reinforcement is shown in the image.

[0175] Silicone mold 822 can also be placed on one or more sides of the mold to create a unique surface. Figure 8C An example of this type of application is shown in the image.

[0176] Figure 9A One embodiment of a system for manufacturing building materials using one or more bio-bonding processes is depicted. The system includes a chamber 978 for processing the building materials under controlled environmental conditions, such as setting and / or regulating the temperature, pressure, and humidity of the building material manufacturing environment. The environmental conditions applied to the aggregate particles are controlled by a pressure, temperature, and humidity controller 990. A frame 992 is arranged within the chamber 978. Although only a single frame 992 is depicted within the chamber 978, additional frames can be processed simultaneously within the chamber 978. In some embodiments, the frame 992 and the chamber 978 may be the same element. Building materials can be formed within the frame 992 while controlled environmental conditions are applied. In some cases, the frame 992 includes a support structure for the aggregate particles within the frame 992. In one example, the frame 992 includes an L-shaped frame or rigid container for forming non-standard 3D shapes, such as L-shaped barriers and artistic shapes.

[0177] As depicted, the system includes a fluid regulator 988 for applying a binder solution and / or feed solution to aggregate particles within a frame 992. The fluid regulator 988 can regulate the fluid pressure (and, in some embodiments, the fluid temperature) of the fluid injected into the frame 992. When a fluid containing a binder solution / feed solution (or another fluid, such as an inoculum, rinsing solution, etc.) is injected into the frame 992 within a processing chamber 978, the fluid regulator 988 can dynamically regulate the fluid flow rate as the building material hardens or forms. The fluid regulator 988 may utilize a pump controller to regulate the fluid pressure and fluid flow direction. Nozzles (e.g., nozzle 989) enable the fluid regulator to inject fluid into the template through one or more inlets not depicted in the frame 992.

[0178] A fluid regulator 988, communicating with a computing system 901, can regulate the temperature of the binder solution applied to the building material within the frame 992 and regulate the rate at which the binder solution is applied to the building material. The fluid regulator 988 may include heating and / or cooling elements for regulating the temperature of the binder solution applied to the building material. A pressure, temperature, and humidity controller 990 is connected to a heat conductor 984 (e.g., a metal grille or metal strip) that is in thermal communication with the chamber 978. The heat conductor 984 may be directly connected to or in physical contact with the frame 992. A tray 986 provides structural support for the building material and the frame 992 within the chamber 978. The heat conductor 984 is arranged between the tray 986 and the chamber 978.

[0179] In some implementations, the pressure, temperature, and humidity controller 990 can regulate the temperature of the building materials (e.g., aggregate particles within the frame 992) within the chamber 978 by heating or cooling the heat conductor 984. The pressure, temperature, and humidity controller 990 can also regulate or adjust the temperature of the building materials within the chamber 978 using temperature-regulated airflow. The pressure, temperature, and humidity controller 990 can regulate the ambient pressure within the chamber 978. The chamber 978 can completely enclose the frame 992 or provide an open or ventilated environment.

[0180] In some implementations, the pressure, temperature, and humidity controller 990 may include a computing system, such as computing system 901. The computing system may include network interfaces, processors, memory, and disks that communicate with each other. The network interfaces, processors, memory, and disks may include physical or virtualized components. In one instance, the network interfaces, processors, memory, and disks are provided by virtualized infrastructure or cloud-based infrastructure. The network interface may allow the computing system to connect to one or more networks. As an example, the network interface may include a wireless network interface and / or a wired network interface. The processor may allow the computing system to execute computer-readable instructions stored in memory to perform the processes described herein. The processor may include one or more processing units, such as one or more CPUs, one or more GPUs, and / or one or more NPUs. The memory may include one or more types of memory (e.g., RAM, SRAM, DRAM, EEPROM, flash memory). The disk may include hard disk drives and / or solid-state drives. In some cases, both memory and disk may include hardware storage devices.

[0181] like Figure 9A As shown, a system using one or more bio-bonding processes to manufacture building materials also includes a feed tank 972 for collecting the remaining portion of the binder solution 973. Remaining or unused portions of the binder solution 973 that are not utilized by the building materials within the frame 992 during the bio-bonding process can be collected and reused during subsequent bio-bonding processes. Filtered and / or recirculated binder solution 973 can be transferred to a fluid regulator 988 via a pump 982. In some cases, particulate matter within the binder solution 973 collected in the feed tank 972 can be allowed to settle within the collection tank, so that suction of fluid from the bottom of the collection tank can provide filtration for the recirculated binder solution 973. In one example, an inlet pipe for supplying recirculated binder solution 973 to pump 982 can be positioned at least 10 inches from the bottom of the feed tank 972 (e.g., the distance 971 between the bottom of the feed tank 972 and the inlet pipe can be 12 inches). The inlet pipe may include an additional filter for removing particles from the recirculated cementing solution 973.

[0182] In some cases, the system will recirculate the cementing solution 973 and re-inject previously used fluids until the pH or conductivity of the fluid reaches a specific pH value (e.g., pH rises above 7.9) and / or the conductivity of the fluid drops below the threshold conductivity or resistance.

[0183] In some embodiments, the fluid containing the cementing solution and / or feed solution contains urea and calcium salts (e.g., calcium chloride or other calcium-containing compounds). 2+ (The salt). In some embodiments, the concentration of urea in the fluid is between 100 mM and 400 mM. In some embodiments, the concentration of calcium chloride in the fluid is between 100 mM and 400 mM.

[0184] In some embodiments, the concentration of urea is from about 180 mM to about 330 mM. In some embodiments, the concentration of urea is from about 180 mM to about 190 mM, from about 190 mM to about 200 mM, from about 200 mM to about 210 mM, from about 210 mM to about 220 mM, from about 220 mM to about 230 mM, from about 230 mM to about 240 mM, from about 240 mM to about 250 mM, from about 250 mM to about 260 mM, from about 260 mM to about 270 mM, from about 270 mM to about 280 mM, from about 280 mM to about 290 mM, from about 290 mM to about 300 mM, from about 300 mM to about 310 mM, from about 310 mM to about 320 mM, or from about 320 mM to about 330 mM. In some embodiments, the concentration of urea is about 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, or 330 mM. In some embodiments, the concentration of urea is about 230 mM. In some embodiments, the concentration of urea is about 240 mM. In some embodiments, the concentration of urea is about 240 mM. In some embodiments, the concentration of urea is about 260 mM. In some embodiments, the concentration of urea is about 270 mM. In some embodiments, the concentration of urea is about 280 mM. In some embodiments, the concentration of calcium chloride is from about 180 mM to about 330 mM. In some embodiments, the concentration of calcium chloride is about 180 mM to about 190 mM, about 190 mM to about 200 mM, about 200 mM to about 210 mM, about 210 mM to about 220 mM, about 220 mM to about 230 mM, about 230 mM to about 240 mM, about 240 mM to about 250 mM, about 250 mM to about 260 mM, about 260 mM to about 270 mM, about 270 mM to about 280 mM, about 280 mM to about 290 mM, about 290 mM to about 300 mM, about 300 mM to about 310 mM, about 310 mM to about 320 mM, or about 320 mM to about 330 mM. In some embodiments, the concentration of calcium chloride is about 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, or 330 mM. In some embodiments, the concentration of calcium chloride is about 230 mM. In some embodiments, the concentration of calcium chloride is about 240 mM. In some embodiments, the concentration of calcium chloride is about 240 mM. In some embodiments, the concentration of calcium chloride is about 260 mM. In some embodiments, the concentration of calcium chloride is about 270 mM.In some embodiments, the concentration of calcium chloride is approximately 280 mM. In some embodiments, the concentration of urea is approximately equal to the concentration of calcium chloride. In some embodiments, the concentration of urea differs from the concentration of calcium chloride.

[0185] Figure 9B Depicting Figure 9A One embodiment of various components of a computing system 901. Components within the computing system 901 may include physical hardware computing devices or virtual computing devices, such as one or more virtual machines. As depicted, the computing system 901 includes hardware-level components and software-level components. Hardware-level components may include one or more processors 170, one or more memories 171, and one or more disks 172. The one or more processors 170 may include one or more processing units, such as one or more CPUs, one or more GPUs, and / or one or more NPUs. The one or more memories 171 may include one or more types of memory (e.g., RAM, SRAM, DRAM, EEPROM, flash memory). The one or more disks 172 may include hard disk drives and / or solid-state drives. Both the one or more memories 171 and the one or more disks 172 may constitute a hardware storage device. A storage device may correspond to one or more memories 171 or one or more disks 172.

[0186] Software-level components can include software applications and computer programs. Environmental conditioner 191 and fluid control application 192 can be stored or implemented using software or a combination of hardware and software. In some cases, software-level components run using dedicated hardware servers. In other cases, software-level components can run using virtual machines or containerized environments running on multiple machines. In various implementations, software-level components can run from the cloud (e.g., software-level components can be deployed using cloud-based computing and storage infrastructure).

[0187] like Figure 9BAs described, software-level components may also include virtualization layer processes, such as virtual machine 173, hypervisor 174, container engine 175, and host operating system 176. Hypervisor 174 may include a native hypervisor (or a bare-metal hypervisor) or a managed hypervisor (or a Type 2 hypervisor). Hypervisor 174 can provide a virtual operating system platform to run one or more virtual machines, such as virtual machine 173. The hypervisor may contain software for creating and running virtual machine instances. Virtual machine 173 may include multiple virtual hardware devices, such as virtual processors, virtual memory, and virtual disks. Virtual machine 173 may include a guest operating system capable of running one or more software applications. Virtual machine 173 may run host operating system 176, on which container engine 175 can run.

[0188] Container Engine 175 can run on top of host operating system 176 to run multiple isolated instances (or containers) on the same operating system kernel of host operating system 176. Containers can facilitate operating system-level virtualization and provide a virtualized environment for running applications and their dependencies. Containerized applications may consist of applications running in isolated runtime environments (or containers). Container Engine 175 can acquire container images and convert them into running processes. In some cases, Container Engine 175 can group the containers that make up an application into logical units (or pods). A pod can contain one or more containers, and all containers in a pod can run on the same node in the cluster. Each pod can serve as a deployment unit of the cluster. Each pod can run a single application instance.

[0189] In some implementations, the components depicted in the computing system 901 (including the environmental conditioner 191 and the fluid control application 192) are implemented in a cloud or virtualized environment that allows the creation of virtual hardware and decoupling it from the underlying physical hardware.

[0190] Environmental condition regulator 191 can configure or regulate one or more environmental parameters (e.g., pressure, temperature, and humidity parameters) during the building material forming process. Fluid control application 192 can configure or adjust... Figure 9AOne or more manufacturing parameters of the fluid regulator 988 (e.g., fluid pressure, fluid temperature, and fluid feed rate parameters). The fluid control application 192 can adjust the fluid pressure to cause the fluid to flow in the opposite direction to gravity. In one example, negative pressure can be used to draw fluid towards the fluid regulator 988, away from the feed tank 972. The fluid control application 192 can inject fluid into the frame 922 during a first time period, and then extract the fluid from the frame 922 during a second time period after the first time period. Changing the direction of fluid flow can improve the stiffness and structural integrity of the resulting building material.

[0191] Figure 9C A flowchart illustrating one embodiment of a process for producing building materials is provided. In one embodiment, Figure 9C process use Figure 9A Systems and / or Figure 9A The framework 992 described herein is used. In some implementations, Figure 9C The process utilizes a building materials manufacturing system, which includes a pressurized environment, such as... Figure 9A The chamber 978 is depicted.

[0192] In step 902, a plurality of aggregate particles are obtained. The plurality of aggregate particles may be provided by a mixture of aggregate materials. The aggregate materials may include sand, gravel, and / or granular materials. In step 904, the plurality of aggregate particles are added to a frame to form or shape a frame-like plurality of aggregate particles. In step 906, a first fluid containing a binding agent is passed through the frame-like plurality of aggregate particles. In step 908, the binding agent is reacted with biological organisms and / or enzymes contained within the first fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles. In step 910, after the frame-like plurality of aggregate particles have solidified, a building material is formed. During the formation of the building material, the building material may be compacted or pressed to increase its density.

[0193] Figure 9D A flowchart illustrating another embodiment of a process for producing building materials is provided. In one embodiment, Figure 9D process use Figure 9A Systems and / or Figure 9A The framework 992 described herein is used. In some implementations, Figure 9D The process utilizes building material manufacturing systems that include pressurized or climate-controlled environments.

[0194] In step 922, multiple aggregate particles are added to or inserted into a frame to form a frame-like plurality of aggregate particles. In step 924, the multiple aggregate particles within the frame are compacted. In step 926, a first fluid containing a binding agent is pumped through the frame-like plurality of aggregate particles. In one embodiment, the pump (e.g., Figure 9A The pump 982 can change the direction of fluid flow during the formation of building materials. In step 928, the binding agent is reacted with biological organisms and / or enzymes contained within the first fluid or within the framework of aggregate particles, for a reaction time sufficient to solidify the framework of aggregate particles into building materials. The building materials may include L-shaped barriers.

[0195] Figure 9E A flowchart illustrating another embodiment of a process for producing building materials is provided. In one embodiment, Figure 9E process use Figure 9A Systems and / or Figure 9A The framework 992 described herein is used. In some implementations, Figure 9E The process utilizes a building material manufacturing system, which includes a pressurized environment or fluid regulator, such as... Figure 9A The fluid regulator 988 in the middle.

[0196] In step 942, a plurality of aggregate particles are obtained. The plurality of aggregate particles may be provided by a mixture of aggregate materials. The aggregate materials may include sand, gravel, and / or granular materials. In step 944, the plurality of aggregate particles are inserted into a support structure to form a shaped plurality of aggregate particles. In step 946, a first fluid containing a binding agent is allowed to flow through the shaped plurality of aggregate particles, wherein the first fluid flows through the support structure in one direction such that the flow direction of the first fluid is opposite to gravity, and / or the first fluid flows through the support structure at a pressure higher than atmospheric pressure. A fluid regulator (e.g., Figure 9A A fluid regulator (988) is used to change or regulate the direction of fluid flow. In step 948, a binding agent is reacted with a biological organism or an enzyme. The biological organism may be present in the first fluid or within the shaped aggregate particles. The enzyme may be present in the first fluid or within the shaped aggregate particles. The binding agent is reacted with the biological organism and / or enzyme for a sufficient time (e.g., two hours) to solidify or bind at least a portion of the shaped aggregate particles. In step 950, after at least a portion of the shaped aggregate particles has solidified or bound, a building material is formed.

[0197] For the purposes of this document, it should be noted that the dimensions of the various features depicted in the figures are not necessarily drawn to scale.

[0198] For the purposes of this document, unless the context clearly indicates otherwise, references to “an implementation,” “one implementation,” “some implementations,” “another implementation,” and other variations thereof in the specification may be used to describe various features, functions, or structures included in at least one or more implementations, and do not necessarily refer to the same implementation.

[0199] For the purposes of this document, a connection can be a direct connection or an indirect connection (e.g., a connection via another component). In some cases, when a component is referred to as being connected to or coupled to another component, that component may be directly connected to the other component or indirectly connected to the other component via an intermediate component. When a component is referred to as being directly connected to another component, there is no intermediate component between that component and the other component.

[0200] For the purposes of this document, the term "based on" may be understood as "at least partially based on".

[0201] For the purposes of this document, without additional context, the use of numerical terms such as “first” object, “second” object, and “third” object may not imply an ordering of objects, but may be used for identification purposes to identify or distinguish individual objects.

[0202] For the purposes of this document, the term "collection" can refer to a "set" of one or more objects.

[0203] For the purposes of this document, the phrases “the first object corresponds to the second object” and “the first object corresponds to the second object” may mean that the first object and the second object are equivalent, similar or related in characteristics or functions.

[0204] For the purposes of this document, the term “or” should be interpreted as both a conjunction and a separator. Unless otherwise explicitly stated, a list of items connected by the conjunction “or” should not be construed as requiring items to be mutually exclusive, but rather as “and / or”. As used herein, the terms “at least one,” “one or more,” and “and / or” are open-ended expressions that are operationally usable as both conjunctions and separators. The phrase “A and / or B” covers embodiments having only element A, only element B, or both element A and element B. The phrase “at least one of A, B, and C” covers embodiments having only element A, only element B, only element C, both element A and element B, both element A and element C, both element B and element C, or all three elements A, B, and C. As used herein, unless otherwise explicitly stated, the indefinite articles “a” and “an” should generally be interpreted as meaning “at least one” or “one or more.”

[0205] For the purposes of this document, whenever the terms "at least," "greater than," or "greater than or equal to" precede the first value in a series of two or more values, the terms "at least," "greater than," or "greater than or equal to" apply to each value in that series. For example, greater than or equal to 1, 2, or 3 is equivalent to greater than or equal to 1, greater than or equal to 2, or greater than or equal to 3.

[0206] For the purposes of this document, whenever the terms “not greater than,” “less than,” or “less than or equal to” precede the first value in a series of two or more values, the terms “not greater than,” “less than,” or “less than or equal to” apply to each value in that series. For example, less than or equal to 3, 2, or 1 is equivalent to less than or equal to 3, less than or equal to 2, or less than or equal to 1.

[0207] Some embodiments disclosed herein envision numerical ranges. When a range exists, it includes the range endpoints. Additionally, each subrange and value within the range exists as explicitly stated. The terms “about,” “approximately,” or “substantially” can mean within an acceptable margin of error for a particular value, which may depend in part on how the value is measured or determined, for example, limitations of the measurement system. For example, “about” can mean within one or more standard deviations according to practice in the art. Alternatively, “about” can mean a range of up to 20%, up to 10%, up to 5%, or up to 1% of a given value. When a particular value is described in the application and claims, unless otherwise stated, it may be assumed that the term “about” means within an acceptable margin of error for that particular value.

[0208] The various embodiments described above can be combined to provide further embodiments. These and other modifications can be made to the embodiments based on the detailed description above. Generally, the terminology used in the following claims should not be construed as limiting the claims to the specific embodiments disclosed in the specification and claims, but should be interpreted to include all possible embodiments and the full scope of equivalents enjoyed by the claims. Therefore, the claims are not limited by this disclosure.

[0209] The public information presented herein covers the topics shown in the following example terms: Clause 1: A method for producing building materials, the method comprising: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; allowing a first fluid containing a binding agent to flow through the frame-like plurality of aggregate particles, wherein the first fluid is introduced into the frame in one direction such that the flow direction is opposite to gravity; and reacting the binding agent with biological organisms and / or enzymes contained in the first fluid or in the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

[0210] Clause 2: A method for producing building materials, the method comprising: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; allowing a first fluid containing a cementing agent to flow through the frame-like plurality of aggregate particles at a pressure higher than atmospheric pressure; and reacting the cementing agent with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

[0211] Clause 3: A method for producing building materials, the method comprising: adding a plurality of aggregate particles into a frame to form a frame-like plurality of aggregate particles; substantially venting air from the gaps between the frame-like plurality of aggregate particles; allowing a first fluid containing a binding agent to flow through the frame-like plurality of aggregate particles; and reacting the binding agent with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles for a reaction time sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

[0212] Clause 4: A method for producing building materials, the method comprising: compacting a plurality of aggregate particles in a frame to reduce the volume of void space between adjacent particles of the plurality of aggregate particles; allowing a first fluid containing a cementing agent to flow through the void space of the plurality of aggregate particles; and reacting the cementing agent with biological organisms and / or enzymes contained in the fluid or within the frame-like plurality of aggregate particles, the reaction time being sufficient to solidify the frame-like plurality of aggregate particles, thereby forming the building material.

[0213] Clause 5: The method of any of the preceding clauses, wherein the first fluid flows through the frame-shaped plurality of aggregate particles by entering through the lower surface or lower part of the surface of the frame and exiting through the upper surface or upper part of the surface of the frame.

[0214] Clause 6: The method of any of the preceding clauses, wherein the fluid flows through the plurality of aggregate particles at a first pressure at a first time, the first pressure being greater than atmospheric pressure.

[0215] Clause 7: The method of Clause 6, wherein the fluid flows through the plurality of aggregate particles at a second time at a second pressure, the second pressure being greater than the first pressure.

[0216] Clause 8: The method of any of the preceding clauses, wherein a second fluid containing a binding agent is passed through the frame-shaped aggregate particles before, during or after the reaction.

[0217] Clause 9: The method of any of the preceding clauses, the method comprising recirculating the first fluid or the second fluid through the frame, for multiple cycles.

[0218] Clause 10: The method of Clause 9, wherein each cycle in the plurality of cycles increases the degree of consolidation of the plurality of aggregate particles.

[0219] Clause 11: The method of any one of Clauses 9-10, wherein the recirculation involves fluid flowing through the frame for a total of at least 3 cycles (e.g., at least 5 cycles or at least 10 cycles).

[0220] Clause 12: The method of any of the preceding clauses, wherein the volume of the first fluid or the second fluid is about 50% to about 500% (e.g., about 75% to about 150%) of the volume of the frame.

[0221] Clause 13: The method of any of the preceding clauses, wherein the volume of the first fluid or the second fluid is about 100% to about 500% (e.g., about 200% to about 300%) of the void volume of the plurality of aggregate particles in the framework.

[0222] Clause 14: The method of any of the preceding clauses, wherein the cementing agent contained in the first fluid comprises the biological organism (or its spores) and / or the enzyme.

[0223] Clause 15: The method of any of the preceding clauses, wherein the cementing agent contained in the second fluid contains nutrients that promote the activity of the biological organism and / or the enzyme.

[0224] Clause 16: The method of any of the preceding clauses, wherein the cementing agent contained in the first fluid contains nutrients that promote the activity of the biological organism and / or the enzyme.

[0225] Clause 17: The method of any one of Clauses 1-16, wherein the cementing agent contained in the first fluid does not contain nutrients that promote the activity of the biological organism and / or the enzyme.

[0226] Clause 18: The method of any of the preceding clauses, wherein the cementing agent comprises the biological organism (or its spores), the enzyme, urea (and / or its derivatives), calcium salt (e.g., CaCl2), nutrients, or a combination of two or more of these substances.

[0227] Clause 19: The method of any of the preceding clauses, wherein the plurality of aggregate particles comprises an admixture of sand and gravel.

[0228] Clause 20: The method of Clause 19, wherein the sand and gravel mixture comprises 1-99% sand and 1-99% gravel by volume.

[0229] Clause 21: The method of Clause 20, wherein the sand and gravel mixture comprises 55-75% sand and 25-45% gravel by volume (e.g., wherein the sand and gravel mixture comprises 66% sand and 34% gravel).

[0230] Clause 22: The method of any one of Clauses 19-21, wherein the plurality of aggregate particles consist substantially of a mixture of the sand and gravel.

[0231] Clause 23: The method of any one of Clauses 19-22, wherein the average particle size of the sand is at least 10 times smaller than the average particle size of the gravel (e.g., at least 20 times, 50 times, or 100 times smaller).

[0232] Clause 24: The method of any of the preceding clauses, the method further comprising adding reinforcing material (e.g., steel bars, glass fiber reinforced bars, or glass fiber bundles) to the frame before or simultaneously with the addition of the plurality of aggregate particles.

[0233] Clause 25: The method of any of the preceding clauses, the method further comprising settling the added plurality of aggregate particles into the mold cavity of the frame.

[0234] Clause 26: The method of Clause 25, wherein settling is carried out by pressing the plurality of aggregate particles and / or applying vibration to the plurality of aggregate particles to reduce the volume of void space within the mold.

[0235] Clause 27: The method of any one of Clauses 25-26, wherein the sedimentation is carried out while the plurality of particles are drying.

[0236] Clause 28: The method of any one of Clauses 25-26, wherein the sedimentation is carried out while the plurality of particles are solvated (e.g., while the plurality of particles are wetted).

[0237] Clause 29: The method of Clause 28, wherein the sedimentation is carried out at least in part by applying a pressurized solvent (e.g., water) to the particles at a pressure configured to increase the bulk density of the particles.

[0238] Clause 30: The method of any of the preceding clauses, wherein the pressure of any fluid flow applied to the plurality of frame-like particles is at least about 1 psi (e.g., at least about 5, 10, 20, 50 or 100 psi).

[0239] Clause 31: The method of any of the preceding clauses, wherein the pressure of any fluid flow applied to the plurality of frame-like particles is from about 1 psi to about 100 psi (e.g., 1 to 5 psi, 1 to 20 psi, 1 to 50 psi, 10 to 50 psi, 10 to 20 psi or 20 to 50 psi).

[0240] Clause 32: The method of any of the preceding clauses, wherein the produced building material has a compressive strength of at least about 3,000 psi (e.g., at least 4,000 psi or at least 6,000 psi), and / or wherein the building material remains undamaged after 25 cycles of the freeze-thaw test of EN 14617-5.

[0241] Clause 33: The method of any of the preceding clauses, wherein the biological organism is an organism (or its spores) that produces urease.

[0242] Clause 34: The method of Clause 33, wherein the organism that produces urease is Bacillus pasteurellii.

[0243] Clause 35: The method of any of the preceding clauses, wherein the enzyme is urease.

[0244] Clause 36: The method of any of the preceding clauses, wherein the method comprises, prior to the reaction, substantially venting air from the void spaces between the plurality of frame-shaped aggregate particles.

[0245] Clause 37: The method of Clause 36, wherein the air is expelled by causing fluid to flow through the frame-shaped aggregate particles.

[0246] Clause 38: The method of Clause 37, wherein the fluid flows in the opposite direction to gravity.

[0247] Clause 39: The method of any one of Clauses 37-38, wherein the air is vented using the pressure difference between the fluid inlet and the fluid outlet.

[0248] Clause 40: The method of any of the preceding clauses, wherein the reaction binds adjacent particles of the plurality of particles together by means of calcium carbonate bridges, thereby forming the building material.

[0249] Clause 41: The method of any of the preceding clauses, the method further comprising reducing the void space between the plurality of adjacent aggregate particles by at least 50% prior to the reaction.

[0250] Clause 42: The method of any of the preceding clauses, wherein the reaction and / or the fluid recirculation are carried out continuously.

[0251] Clause 43: The method of any of the preceding clauses, wherein fluid flows into the frame from the top or upper surface of the frame.

[0252] Clause 44: The method of any of the preceding clauses, wherein fluid flows into the frame from one or more sides of the frame.

[0253] Clause 45: The method of any of the preceding clauses, wherein the frame includes a plurality of fluid outlets.

[0254] Clause 46: The method of any of the preceding clauses, wherein the cells of the organism or the enzymes are added to the plurality of aggregate particles before the plurality of aggregate particles are added to the frame, or wherein the cells of the organism or the enzymes are added to the frame at substantially the same time as the plurality of aggregate particles.

[0255] Clause 47: The method of Clause 46, wherein the cells of the organism comprise spores, germinating spores, vegetative cells and / or activated enzyme-producing cells.

[0256] Clause 48: A reusable frame for producing precast bioconcrete building materials, the frame comprising: a plurality of panels configured to: (i) be temporarily fixed together during curing of the precast bioconcrete building materials to form a fluid coupling system, and (ii) be released to allow the precast building materials to be demolded from a cavity formed when the plurality of panels are fixed together; a binder inlet; a binder outlet; wherein the cavity formed when the panels are fixed together has a volume of at least 50 L (e.g., at least 100 L or at least 1000 L), and / or wherein the cavity is a 3D shape that is not cubic or cuboid, the binder inlet being located on at least one of the plurality of panels and configured to be fluidly coupled to the cavity when the plurality of panels are temporarily fixed, and the binder outlet being located on at least one of the plurality of panels and configured to be fluidly coupled to the cavity when the plurality of panels are temporarily fixed.

[0257] Clause 49: A reusable frame of Clause 48, wherein the bonding agent inlet is configured to be located on a panel lower than the bonding agent outlet when the plurality of panels are temporarily fixed.

[0258] Clause 50: A reusable frame of any of Clauses 48-49, wherein the cementing agent inlet and / or the cementing agent outlet are configured to allow pressurization of fluid within the cavity of the reusable frame.

[0259] Clause 51: A reusable frame of any one of Clauses 48-50, the frame comprising one or more vents configured to allow air to escape from the mold cavity.

[0260] Clause 52: A reusable frame of any of Clauses 48-51, wherein the plurality of panels comprises at least one patterned panel configured to alter the aesthetic appearance of one or more surfaces of the prefabricated building material.

[0261] Clause 53: A reusable frame of any of Clauses 48-52, wherein the plurality of panels are configured in a modular manner, which allows for the manufacture of multiple types or quantities of precast bioconcrete material using the same reusable frame.

[0262] Clause 54: A reusable frame of any one of Clauses 48-53, wherein the precast bioconcrete material produced by said frame is: a variety of paving bricks, L-shaped walls, modular wall panels and / or New Jersey-style railings.

[0263] Clause 55: A system for producing precast bioconcrete building materials, the system comprising a reusable frame, fluid manifold, and pump of any of Clauses 48-54.

[0264] Clause 56: The system of Clause 55, wherein the pump is fluidly connected to the fluid manifold, the cementing agent inlet of the reusable frame, and / or the cementing agent outlet.

[0265] Clause 57: A system of any one of Clauses 55-56, the system further comprising a recirculation tank configured to recirculate fluid through the reusable frame.

[0266] Clause 58: A system of any one of Clauses 55-57, the system further comprising a reagent storage tank configured to provide fresh bonding reagent to the recycling tank, to the mold cavity of the reusable frame, or both.

[0267] Clause 59: A system of any one of Clauses 55-58, the system further comprising one or more effluent storage tanks configured to accumulate waste liquid and / or fluids that have been depleted of the binding agent.

[0268] Clause 60: A system of any one of Clauses 55-59, wherein the system is configured to perform the method of any one of Clauses 1-37.

[0269] Clause 61: A building material manufactured by any of the methods described in the preceding clauses.

[0270] Clause 62: Building materials of Clause 61, wherein the building materials comprise 3D shapes that are not cubes or cuboids.

[0271] Clause 63: Any method, system, reusable frame, or building material mentioned in any of the preceding clauses, wherein the building material comprises a geometry that is not a simple geometry.

Claims

1. A method for producing building materials, the method comprising: Multiple aggregate particles are added into a frame to form a frame-like structure of multiple aggregate particles; A first fluid containing a binding agent is allowed to flow through the frame-like plurality of aggregate particles, wherein the first fluid is introduced into the frame from one direction such that the flow direction is opposite to gravity; and The cementing agent is reacted with the biological organisms or enzymes contained in the first fluid or in the multiple aggregate particles in the framework, and the reaction time is sufficient to solidify the multiple aggregate particles in the framework, thereby forming the building material.

2. A method for producing building materials, the method comprising: Multiple aggregate particles are added into a frame to form a frame-like structure of multiple aggregate particles; A first fluid containing a binding agent flows through the framework of aggregate particles at a pressure higher than atmospheric pressure; and The cementing agent is reacted with the biological organisms or enzymes contained in the first fluid or in the multiple aggregate particles in the framework, and the reaction time is sufficient to solidify the multiple aggregate particles in the framework, thereby forming the building material.

3. The method as described in any of the preceding claims, further comprising compacting the plurality of aggregate particles in the frame to reduce the void space volume between adjacent particles of the plurality of aggregate particles.

4. The method of claim 3, wherein the compaction of the plurality of aggregate particles in the frame is performed before the first fluid containing the cementing agent flows through the frame-shaped plurality of aggregate particles.

5. The method of any of the preceding claims, wherein the first fluid flows through the frame-shaped plurality of aggregate particles by entering through the lower surface or lower part of the surface of the frame and exiting through the upper surface or upper part of the surface of the frame.

6. The method as described in any of the preceding claims, wherein the fluid flows through the plurality of aggregate particles at a first pressure at a first time, the first pressure being greater than atmospheric pressure.

7. The method of claim 6, wherein the fluid flows through the plurality of aggregate particles at a second time after the first time at a second pressure, the second pressure being greater than the first pressure.

8. The method as claimed in any of the preceding claims, wherein a second fluid containing the binding agent is passed through the framework of aggregate particles before, during, or after the reaction step.

9. The method of claim 8, further comprising recirculating the first fluid or the second fluid through the frame for multiple cycles.

10. The method of claim 9, wherein each cycle in the plurality of cycles increases the degree of consolidation of the plurality of aggregate particles.

11. The method of any of the preceding claims, wherein the cementing agent contained in the first fluid comprises the biological organism (or its spores) and / or the enzyme.

12. The method of any of the preceding claims, wherein the cementing agent contained in the first fluid comprises nutrients that promote the activity of the biological organism and / or the enzyme.

13. The method of any of the preceding claims, further comprising adding reinforcing material to the frame before or simultaneously with the addition of the plurality of aggregate particles to the frame.

14. The method of claim 13, wherein the reinforcing material comprises steel bars.

15. The method as described in any of the preceding claims, further comprising vibrating the plurality of aggregate particles prior to the reaction step.

16. The method of claim 15, wherein the vibration comprises vibrating the plurality of aggregate particles using ultrasonic waves.

17. The method of claim 15, wherein the vibration comprises generating sound using an ultrasonic probe located within the frame-like plurality of aggregate particles.

18. A building material manufactured by the method as described in any one of the preceding claims.

19. The building material of claim 18, wherein the building material is or comprises a 3D shape that is not a cube or cuboid.

20. The building material of claim 18, wherein the building material comprises glass fiber reinforced steel bars.

21. A method for producing building materials, the method comprising: Multiple aggregate particles are inserted into the support structure to form multiple shaped aggregate particles; A first fluid containing a binding agent is allowed to flow through the shaped aggregate particles, wherein the first fluid flows through the support structure in one direction such that the flow direction of the first fluid is opposite to gravity, or the first fluid flows through the support structure at a pressure higher than atmospheric pressure. as well as The building material is produced by reacting the cementing agent with biological organisms or enzymes within the first fluid or within the shaped aggregate particles for a reaction time sufficient to solidify or bind at least a portion of the shaped aggregate particles.

22. The method of claim 21, further comprising: Detect the back pressure of the first fluid flow; Determine whether the back pressure is greater than or less than the threshold back pressure; as well as In response to detecting that the back pressure is greater than or less than the threshold back pressure, the pressure is adjusted to allow the first fluid to flow through the shaped aggregate particles.

23. The method of claim 22, wherein: The pressure adjustment includes increasing the pressure to allow the first fluid to flow through the shaped aggregate particles.

24. The method of claim 22, wherein: The adjusted pressure causes an increase in the flow rate of the first fluid through the formed aggregate particles.

25. The method of claim 22, wherein: The pressure adjustment includes reducing the pressure to allow the first fluid to flow through the shaped aggregate particles.

26. The method of claim 22, wherein: The adjusted pressure causes a decrease in the flow rate of the first fluid through the formed aggregate particles.

27. The method of claim 21, further comprising: The back pressure of the first fluid flowing through the formed aggregate particles is detected to be greater than or less than a threshold back pressure; as well as In response to detecting that the back pressure is greater than or less than the threshold back pressure, the flow of the first fluid through the formed plurality of aggregate particles is adjusted.

28. The method of claim 25, wherein: The adjustment of the flow of the first fluid includes one of the following: adjusting the flow direction of the first fluid through the formed aggregate particles or adjusting the flow rate of the first fluid through the formed aggregate particles.

29. The method of claim 21, further comprising: The change in conductivity of the first fluid was detected to exceed a threshold amount; as well as In response to detecting a change in the conductivity of the first fluid exceeding the threshold amount, the flow of the first fluid through the shaped aggregate particles is adjusted.

30. The method of claim 22, wherein: The pressure adjustment includes increasing or decreasing the rate at which the pressure used to increase or decrease the flow of the first fluid through the shaped aggregate particles.

31. The method of claim 22, wherein: The regulating pressure includes increasing or decreasing the rate at which the pressure used to increase or decrease the fluid flow through the shaped plurality of particles based on the difference between the detected back pressure and the threshold back pressure.

32. A system for manufacturing building materials, the system comprising: A storage device for storing instructions, which, when executed, cause the system to perform operations including: Multiple aggregate particles are arranged into a support structure to form multiple shaped aggregate particles; A fluid containing a binding agent is flowed through the shaped aggregate particles, wherein the fluid flows through the support structure in one direction such that the flow direction of the fluid is opposite to gravity, or the fluid flows through the support structure at a pressure higher than atmospheric pressure. as well as The building material is shaped, which includes reacting the cementing agent with a biological organism or enzyme within the fluid or within the shaped aggregate particles for a reaction time sufficient to solidify or bond at least a portion of the shaped aggregate particles.

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