Controlled crystal growth compositions and methods for producing same

Abstract

Described herein are novel construction material compositions, systems, and methods for their production. Biocement technology is described that monitors and adjusts environmental and process controls during the production of biocement products. Construction materials with advantageous properties, such as increased compressive strength, may be produced using biocement technology. In some cases, the application and adjustment of temperature, pH, and humidity are used to selectively control the rate of biocement formation within various planar sections of the construction material. For example, a planar section of the construction material that includes a non-preferential surface (or a surface to which a cementing solution is applied) may form biocement at a slower rate than other planar sections of the construction material that are at least a threshold distance away from the non-preferential surface.

Description

[Technical Field]

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 488,397, filed March 3, 2023, which is incorporated herein by reference in its entirety. [Background technology]

[0002] Biocement technology provides cost-effective, high-strength building materials, structural materials, and concrete that can have a substantially reduced carbon emission footprint compared to traditional building materials and concrete. Thus, improved biocement compositions and processes may facilitate the substitution of biocement products for traditional building materials and concrete. Summary of the Invention [Means for solving the problem]

[0003] (Summary of the Invention) Biocement technology utilizes microorganisms to improve the mechanical and structural properties of construction materials. In some cases, through microbially induced calcium carbonate precipitation (MICP), microorganisms can react with chemical components to produce minerals in the form of organic-inorganic compounds that act as binders in the construction material. In some cases, environmental and process controls can be used to ensure that a surface (or planar section adjacent to the exterior) of a construction material to which a cementing solution containing a cementing reagent is applied (e.g., using a fluid delivery system to apply the cementing solution to the surface of the construction material) forms biocement at a slower rate than other portions or planar sections of the construction material. The technical benefits of reducing the rate of biocement formation within one or more planar sections of the construction material near or adjacent to the surface to which the cementing solution is applied (e.g., a planar section comprising the top 1 cm of the construction material) include reducing problems associated with clogging, reducing the overall cost of manufacturing the construction material, increasing the compressive strength of the construction material, and reducing manufacturing variability in the properties of the construction material.

[0004] In some embodiments, the application and adjustment of temperature, pH, and / or humidity during the manufacture of the construction material is used to selectively control the rate of biocement formation within various planar sections of the construction material. In one example, planar sections of the construction material that include a non-preferential surface (or the surface to which the cementing solution is applied) form biocement at a slower rate than other planar sections of the construction material that are at least a threshold distance away from the non-preferential surface.

[0005] In some embodiments, the temperature of the construction material before and during biocementation and the temperature of the feed solution being fed to the construction material can vary independently during the production of the construction material. In one example, the temperature of the feed solution can be less than the temperature of the construction material during the biocementation process. In another example, during the biocementation process, the temperature of the feed solution can initially be less than the temperature of the construction material for a first period of time, and then increased for a second period of time following the first period. In another example, the temperature of the feed solution can be less than the temperature of the construction material for a first period of time, and then increased to a temperature greater than the temperature of the construction material for a second period of time following the first period of time. During the formation of microbial calcite precipitates in the construction material, the temperature of the construction material and the humidity of the environment in which the construction material is located can be adjusted to improve the compressive strength achieved in the construction material.

[0006] In some embodiments, biocement techniques are provided that monitor and adjust environmental and process controls to ensure that construction materials receiving a cementing solution containing a cementing reagent at a non-preferential surface (or surface to which the cementing solution is applied) form biocement at a slower rate in planar sections of the construction material near or adjacent to the non-preferential surface compared to other planar sections of the construction material away from or not adjacent to the non-preferential surface. In one example, the rate of biocement formation for planar sections comprising the top 1 cm of the construction material is at least 20% to 50% slower than the rate of biocement formation for one or more other planar sections of the construction material (e.g., planar sections comprising the bottom 10 cm of the construction material). The temperatures of the construction material and cementing solution may be varied during the production of the construction material to reduce the rate of biocement formation in planar sections near or adjacent to the non-preferential surface.

[0007] According to some embodiments, technical benefits of the controlled crystal growth compositions and methods of producing the controlled crystal growth compositions disclosed herein include reduced production time for construction materials, increased throughput of construction materials, increased flexural strength, and increased compressive strength.

[0008] This Summary is provided to introduce a brief description of some aspects of the disclosed technology in a simplified form, which are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended that this Summary be used to limit the scope of the claimed subject matter. Moreover, the claimed subject matter is not limited to implementations that solve any or all of the disadvantages noted in any part of the present disclosure.

[0009] Like numbered elements may refer to common components in various figures. [Brief explanation of the drawings]

[0010] [Figure 1A]1 illustrates an exemplary formwork used to fabricate construction materials. [Figure 1B] 1 illustrates one embodiment of a cross-sectional view of a construction material. [Figure 1C] 1C illustrates one embodiment of a cross-sectional view of the construction material shown in FIG. 1B. [Figure 1D] FIG. 1C illustrates one embodiment of a side view of the construction material shown in FIG. 1B. [Figure 1E] 1E illustrates one embodiment of aggregate particles in the construction material of FIG. 1D prior to compaction. [Figure 1F] 1E illustrates one embodiment of aggregate particles in the construction material of FIG. 1D after compaction of the aggregate particles. [Figure 1G] 1 illustrates one embodiment of experimental results showing average compressive strength for construction materials over a range of wet green densities for the construction materials. [Figure 1H] 1 shows one embodiment of a graph illustrating the percentage of total pore volume versus pore diameter for a construction material. [Figure 1I] 1 illustrates one embodiment of experimental results showing the average change in electrical conductivity for construction materials over a range of average dry green densities for the construction materials. [Figure 1J] 1 illustrates one embodiment of a graph showing total slice porosity over a horizontal slice location from a non-preferential surface of a construction material. [Figure 1K] 1 illustrates one embodiment of experimental results showing total open pore porosity versus number of slices through a material of construction. [Figure 1L] 1 illustrates one embodiment of a construction material that includes aggregate particles that are bound together using calcium carbonate. [Figure 1M] 1 illustrates one embodiment of experimental results showing compressive strength versus wet density and compressive strength versus dry density of construction materials. [Figure 1N] 1 illustrates one embodiment of experimental results showing the percentage of calcium carbonate relative to wet density and the percentage of calcium carbonate relative to dry density of a construction material. [Figure 2]Figure 2B shows an SEM image of the top layer of an exemplary construction material. Figure 2B shows an enlarged image of the area in Figure 2A. [Figure 3] Figure 3B shows an SEM image of the upper intermediate surface layer of an exemplary construction material. Figure 3B shows an enlarged image of the area in Figure 3A. [Figure 4] Figure 4B shows an SEM image of the bottom intermediate surface layer of an exemplary construction material. Figure 4B shows a magnified image of the area in Figure 4A. [Figure 5A] 1 illustrates one embodiment of a system for producing construction materials using one or more biocementation processes. [Figure 5B] 1 shows a flowchart describing one embodiment of a process for producing construction materials. [Figure 5C] 1 shows a flowchart describing an alternative embodiment of a process for producing construction materials. [Figure 5D] 1 shows a flowchart describing an alternative embodiment of a process for producing construction materials. DETAILED DESCRIPTION OF THE INVENTION

[0011] As used herein, the terms "construction material" or "construction materials" generally refer to an article comprising elements or subcomponents that are bound together by adhesive bonds (e.g., cementitious bonds) or bridges. In some cases, the bonds or bridges in construction materials include binders such as calcium carbonate. Construction materials may also include individual physical objects of defined shape that are incorporated into, for example, a building, structure, or work.

[0012] Some construction materials may contain biocement products. Examples of biocement products include, but are not limited to, bioconcrete, biocement-coated aggregates, and articles made from the same. As used herein, the term "biocement" generally refers to any binder that can be generated through biological mechanisms (e.g., enzymatic processes) that adheres to or encapsulates particles of solid material (e.g., aggregate particles). The binder may directly connect two or more aggregate particles or indirectly connect two or more aggregate particles through one or more linkages or bridges in the construction material. The one or more linkages or bridges in the construction material may provide structural support for the construction material and / or provide a structural connection between at least two of the aggregate particles in the construction material. In some cases, aggregate particles include sand, crushed stone, and / or gravel. The shape of the aggregate particles may be classified as either angular, semi-angular, semi-rounded, or rounded. An example of a biocement includes calcium carbonate bound to existing particles of solid material formed by microbially induced calcium carbonate precipitation (MICP). Further examples include biologically sintered metal carbonates, such as, but not limited to, calcium carbonate, magnesium carbonate, barium carbonate, or strontium carbonate.

[0013] As used herein, the term "crosslinked calcium carbonate" generally refers to calcium carbonate that is between, connects, and / or bonds together at least two portions, such as aggregate particles. Together with the at least two portions, the crosslinked calcium carbonate provides a continuous piece comprising the at least two portions and the crosslinked calcium carbonate. The calcium carbonate may be a solid, such as a precipitate. Calcium carbonate may be formed from the reaction of calcium ions with carbonate ions in an aqueous solution, with the resulting calcium carbonate integrated into a bulk composite material comprising calcium carbonate and aggregate particles.

[0014] As used herein, the term "uncrosslinked calcium carbonate" generally refers to calcium carbonate that is not connected or bonded together to at least two moieties, such as aggregate particles. Uncrosslinked calcium carbonate may be a precipitate that is connected to only one moiety, such as an aggregate particle, or a precipitate that is not connected to any aggregate particles. Uncrosslinked calcium carbonate may be bound to less than one moiety.

[0015] As used herein, the terms "aggregate" or "aggregate particles" may be used interchangeably and generally refer to any type of granular material that can be bound together into larger particles or consolidated solids by biocement bonds or crosslinks. Non-limiting examples of aggregate include sand, crushed stone, tailings, or combinations thereof, etc.

[0016] As used herein, the term "cementation reagent" generally refers to any combination of growth nutrients or starting materials that, when combined and reacted, produce a binder through a biological mechanism. For example, an enzyme (or an organism containing an enzyme) can result in the enzymatic formation of a biocement, such as calcium carbonate, that binds adjacent aggregate particles together. For example, the cementation reagent in a urea hydrolysis-based biocementation system may include urea (or another suitable nitrogen source), a soluble calcium source (e.g., calcium chloride, calcium acetate, calcium phosphate, calcium lactate, calcium nitrate, etc.), nutrients that promote urease activity (which may vary depending on whether pure enzymes or urease-producing cells are used), and urease for the formation and precipitation of calcium carbonate biocement. In a calcium carbonate-based biological sinter biocementation system, an example of a biocementation reagent may include calcium carbonate, nutrients that promote enzymatic acid production, and an acid-producing enzyme that generates an acid that dissolves the calcium carbonate. The biocementation reagents for such systems may include a second set of nutrients and a second enzyme that together promote the pH drop and re-precipitation of calcium carbonate to form biocement.

[0017] As used herein, the terms "produce," "production," and "producing," with respect to calcium carbonate in the presence of an enzyme or biological organism, refer to a biological reaction enabled by the enzyme or biological organism to create conditions for the formation of calcium carbonate from starting materials such as calcium ions, carbonate ions, or other possible chemical entities. For example, an enzyme that produces carbonate ions or calcium ions can be referred to as enzyme-produced calcium carbonate. An enzyme that alters the pH to allow calcium carbonate precipitation can also be referred to as enzyme-produced calcium carbonate.

[0018] As used herein, the term microbially induced calcium carbonate precipitation (MICP) (also known as microbially induced calcite precipitation) generally refers to the production of calcium carbonate using at least one enzyme or biological organism capable of forming either calcium ions or carbonate ions, or altering the pH of the environment to precipitate calcium carbonate.

[0019] As used herein, "RPM" and "rpm" are used as units of instantaneous rotational speed equal to revolutions per minute if the speed is maintained for one full minute (i.e., 100% duty cycle).

[0020] Construction materials The construction materials described herein can take many different forms and shapes. An exemplary construction material, such as a unit or brick having a top surface, four vertical sides, and a bottom surface, may be used to illustrate many features of the disclosed embodiments. However, the construction material is not limited to only brick forms. For example, another exemplary construction material can be a rounded tile having a top surface, four vertical circular sides, and a bottom surface.

[0021] Structural biocement-based concrete (e.g., biocement bricks) can rely on the construction of interconnected calcium carbonate crystals to bind surrounding aggregate particles together. While biocement formation can be a product of microbially induced calcite formation, MICP can result in calcium carbonate that is not involved in the formation of structural biocement (e.g., isolated calcium carbonate crystals that are not bound to multiple aggregates).

[0022] In some cases, the connected biocement crosslinks may form as uniformly as possible throughout the aggregate matrix / network, binding adjacent aggregate particles together, thereby ensuring structural integrity throughout the product (e.g., one area may not be significantly stronger or weaker than another area). In some cases, product structural integrity may be achieved by distributing the MICP within the body of the biocement-based concrete such that the concentrations or weight percentages of crosslinked calcium carbonate or calcium to silicon ratio at various cross sections of the product differ from each other by no more than 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0023] When the MICP reaction forms unconnected, isolated, non-crosslinked calcium carbonate crystals, these crystals can fill the pore space between aggregate particles, preventing the formation of additional calcium carbonate required for structural crosslinking, known as clogging. Furthermore, calcium- and urea-containing solutions are directionally deposited on aggregate substrates if biocement is produced at a faster rate at the surface of solution deposition (non-preferential surfaces). The reduction in pore space due to biocement formation or clogging can prevent deeper biocement formation within the unit / biocement-based concrete. In some cases, when homogeneous biocementation (e.g., due to low variability in MICP formation within the body of the unit) is difficult to achieve, another goal may be to produce biocement at a higher concentration at the surface farthest from the surface of solution deposition (preferential surfaces). The formation of nonstructural, unconnected calcium carbonate crystals concentrated at the surface of the material can occur when the pore space is reduced to the point where the deposited solution can no longer penetrate the interior of the unit. This phenomenon is described as "crashout" and indicates the formation of calcium carbonate on the surfaces of the unit. Prevention of crashout is actually desirable to reduce direct material costs while improving product performance, consistency, and manufacturing reproducibility. The early formation of crashout is an indication that biocement or clogging occurs first on the non-preferential surfaces (or solution-adhered surfaces).

[0024] In some embodiments, actual prevention or reduction of crashout is achieved when (a) the applied solution does not contain particulate matter that could clog the aggregate pore space in a non-structural manner, and / or (b) the rate of cementation is not as fast (or slower) on the non-preferential surface (or solution-applied surface) or the rate of cementation is below a rate threshold.

[0025] Regarding (a): After exploring conditions that could reduce the formation of non-crosslinked calcium carbonate in the crashout, the following conditions were identified: filtration is used for the feed solution to prevent inert materials, such as loose aggregate and / or plant matter, from circulating in the feed calcium and / or urea solution. However, while the feed solution can be practically non-sterile, contamination from microorganisms in the aggregate matrix can contaminate the solution as planktonic cells. When MICP occurs outside the aggregate network but in the solution surrounding it, individual, isolated, unconnected calcium carbonate crystals are formed, which can also create granular material in the solution outside the aggregate. Therefore, it is also beneficial to inhibit / reduce biological activity (generating enzymes or biological organisms) in the solution, so that MICP occurs primarily only in the aggregate substrate where biocement formation is desired. In fact, biological activity can be successfully inhibited by applying UV radiation treatment and / or introducing ozone and / or blowing fresh air over the top of the solution outside the aggregate network.

[0026] Regarding (b): One option is to use environmental and process controls to ensure that non-preferred surfaces cannot build biocement faster than preferred surfaces can. In some cases, the non-preferred surface is on top when the feed solution can be deposited from a fluid delivery system that relies on gravity to apply the feed solution. The rate of biocement formation can be correlated to both the metabolic activity of microorganisms or enzymes and their propagation rate (e.g., fermentation, doubling rate). Temperature, nutrient availability, and respiration can affect the biological activity of microorganisms or enzymes. Thus, options include: (a) controlling the temperature of the process so that the temperature at or near the non-preferential surface is no higher than (or is lower than) the temperature at or near the preferred surface, which can be controlled by ensuring that the aggregate substrate is warmer than the solution applied to the non-preferential surface; (b) ensuring that nutrients in the feed solution are completely dissolved so that they can be distributed homogeneously throughout the unit; and / or (c) in the case of anaerobic or facultatively anaerobic microorganisms used in the MICP process, ensuring that sufficient oxygen is available for microbial respiration, which can be achieved through regular air exchange in closed systems or natural ventilation in open systems.

[0027] Described herein is a construction material comprising a plurality of aggregate particles, crosslinked calcium carbonate crystals between at least two members of the plurality of aggregate particles, uncrosslinked calcium carbonate crystals, and at least one biological organism or enzyme that produces at least a portion of the crosslinked calcium carbonate crystals. The construction material may comprise at least one surface and a body encapsulated by the at least one surface. The construction material may comprise: (i) a first average concentration of uncrosslinked calcium carbonate crystals at or near the at least one surface that is less than or equal to a second average concentration of crosslinked calcium carbonate crystals at or near the at least one surface; or (ii) the second average concentration differs by no more than 70% from a third average concentration of crosslinked calcium carbonate crystals at or near a cross section of the body.

[0028] In some embodiments, the construction material may include (i) a first average concentration of non-crosslinked calcium carbonate crystals at or near at least one surface that is less than or equal to a second average concentration of crosslinked calcium carbonate crystals at or near at least one surface, or (ii) the second average concentration differs by no more than 70% from a third average concentration of crosslinked calcium carbonate crystals at or near a cross-section of the body.

[0029] In some embodiments, a first average concentration of non-crosslinked calcium carbonate crystals at or near at least one surface is less than or equal to a second average concentration of crosslinked calcium carbonate crystals at or near at least one surface. In some embodiments, the first average concentration is less than or equal to the second average concentration. In some embodiments, the first average concentration is less than or equal to 99%, 95%, 90%, 85%, 80%, 75%, 70%, 65%, or 60% of the second average concentration. In some embodiments, the first average concentration is between about 30% and about 100% of the second average concentration, between about 35% and about 95%, between about 40% and about 90%, between about 45% and about 85%, between about 50% and about 80%, or between about 55% and about 75% of the second average concentration. In some embodiments, the first average concentration is approximately the same as the second average concentration. In some embodiments, the first average concentration is less than or equal to 170%, 165%, 160%, 155%, 150%, 145%, 140%, 135%, 130%, 125%, 120%, 115%, 110%, or 105% of the second average concentration.

[0030] In some embodiments, the second average concentration differs from the third average concentration by 50% or less. In some embodiments, the second average concentration differs from the third average concentration by 69%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10% or less. In some embodiments, the second average concentration differs from the third average concentration by about 10% to about 70%, about 15% to about 65%, about 20% to about 60%, about 25% to about 55%, about 30% to about 50%, or about 35% to about 45%. In some embodiments, the second average concentration differs from the third average concentration by 50% or less. In some embodiments, the second average concentration differs from the third average concentration by no more than 69%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0031] In some embodiments, the construction materials described herein have at least one surface comprising a first surface and a second surface, and the first average at or near the first surface differs from the first average at or near the second surface by no more than 50%. In some embodiments, the first average concentration at or near the first surface differs from the first average concentration at or near the second surface by no more than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0032] (c) one or more walls connecting the first and second surfaces; and (d) a body encapsulated by the first surface, the second surface, and the one or more walls; (e) a plurality of aggregate particles; (f) crosslinked calcium carbonate crystals between at least two members of the plurality of aggregate particles; (g) non-crosslinked calcium carbonate crystals; and (h) at least one biological organism or enzyme that produces at least a portion of the crosslinked calcium carbonate crystals, wherein a first average concentration of non-crosslinked calcium carbonate crystals at the first surface is at least about 10% higher than a second average concentration of non-crosslinked calcium carbonate crystals at the second surface.

[0033] In some embodiments, the first average concentration is at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, or at least about 100% higher than the second average concentration. In some embodiments, the first average concentration is at least about 10% higher than a third average concentration of non-crosslinked calcium carbonate crystals at or near a cross-section of the body. In some embodiments, the first average concentration is at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, or at least about 100% higher than the third average concentration. In some embodiments, (i) the first average concentration is higher than the fourth average concentration of crosslinked calcium carbonate crystals at or near the first surface, or (ii) the fourth average concentration differs from the fifth average concentration of crosslinked calcium carbonate crystals at or near the cross section of the body by no more than 70%. In some embodiments, the fourth average concentration differs from the fifth average concentration by no more than 69%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%. In some embodiments, the at least one biological organism or enzyme comprises urease or cells of a urease-producing microorganism. In some embodiments, the at least one biological organism or enzyme comprises an acid-producing enzyme or cells of an acid-producing microorganism. In some embodiments, the at least one biological organism or enzyme comprises carbonic anhydrase or cells of a carbonic anhydrase-producing microorganism. In some embodiments, the at least one biological organism or enzyme comprises a urea-producing microorganism. In some embodiments, the average compressive strength of the construction material is at least about 1,500 pounds per square inch (psi).In some embodiments, the average compressive strength is at least about 1,500, 1,600, 1,700, 1,800, 1,900, 2,000, 2,200, 2,400, 2,600, 2,800, 2,900, 3,000, 3,200, 3,400, 3,600, 3,800, 4,000, 4,200, 4,400, 4,600, 4,800, 5,000, 5,200, 5,400, 5,600, 5,800, 6,000, 6,200, 6,400, 6,600, or 6,800 psi.

[0034] Calcium Carbonate Weight Percentage (c) one or more walls between and connecting the first and second surfaces; (d) a body encapsulated by the first surface, the second surface, and the one or more walls, the body comprising a plurality of aggregate particles; (e) calcium carbonate; and (f) at least one biological organism or enzyme that produces at least a portion of the calcium carbonate formed between at least two members of the plurality of aggregate particles, wherein a first average weight percentage of calcium carbonate on the first surface differs by no more than 50% from a second average weight percentage of calcium carbonate on the second surface.

[0035] In some embodiments, the first average weight percentage differs from the third average weight percentage of calcium carbonate over the cross section of the body by no more than 50%. In some embodiments, the first average weight percentage differs from the second average weight percentage by no more than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%. In some embodiments, the first average weight percentage differs from the third average weight percentage by no more than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0036] porosity Described herein is a construction material comprising: (a) a first surface; (b) a second surface substantially opposite the first surface; (c) one or more walls between and connecting the first and second surfaces; (d) a body encapsulated by the first surface, the second surface, and the one or more walls, the body comprising a plurality of aggregate particles; (e) calcium carbonate; and (f) at least one biological organism or enzyme that produces at least a portion of the calcium carbonate formed between at least two members of the plurality of aggregate particles, wherein the construction material has a first average porosity of 15% to 50%.

[0037] In some embodiments, porosity can be measured by X-ray computed tomography data collected from two-dimensional slices to generate a three-dimensional image of the sample, from which the porosity of the sample can be calculated. In some embodiments, porosity distribution can be determined by mercury intrusion porosimetry (MIP) analysis, which can provide information about the size and distribution of pores present in the sample. In some embodiments, the porosity of a sample can be estimated by performing tests on how much water the sample can absorb.

[0038] In some embodiments, the first average porosity of the first surface differs from the second average porosity of the second surface by no more than 50%, hi some embodiments, the first average porosity differs from the second average porosity by no more than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0039] In some embodiments, the first average porosity of the first surface differs from the second average porosity of the second surface by 50% or less, hi some embodiments, the first average porosity differs from the second average porosity by 51%, 60%, 70%, 80%, 90%, 100%, 110%, 120%, 130%, 140%, 150%, 160%, 170%, 180%, 190%, 200% or more.

[0040] In some embodiments, the first average porosity of the first surface differs from the third average porosity across the cross section of the body by no more than 50%, hi some embodiments, the first average porosity differs from the third average porosity by no more than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0041] In some embodiments, the first average porosity of the first surface differs from the third average porosity of the cross section of the body by more than 50%. In some embodiments, the first average porosity differs from the third average porosity by no more than 51%, 60%, 70%, 80%, 90%, 100%, 110%, 120%, 130%, 140%, 150%, 160%, 170%, 180%, 190%, 200% or more.

[0042] In some embodiments, the first average porosity of the first surface is less than 50% of the second average porosity of the second surface, hi some embodiments, the first average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity.

[0043] In some embodiments, the first average porosity of the first surface is less than 50% of the third average porosity across the cross section of the body, hi some embodiments, the first average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the third average porosity.

[0044] In some embodiments, the first average porosity of the first surface is less than 50% of the third average porosity of the cross section of the body, and the third average porosity is less than 50% of the second average porosity of the second surface. In some embodiments, the first average porosity is less than 49% of the third average porosity, and the third average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity. In some embodiments, the first average porosity is less than 45% of the third average porosity, and the third average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity. In some embodiments, the first average porosity is less than 40% of the third average porosity, and the third average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity. In some embodiments, the first average porosity is less than 35% of the third average porosity, and the third average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity. In some embodiments, the first average porosity is less than 30% of the third average porosity, and the third average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity. In some embodiments, the first average porosity is less than 25% of the third average porosity, and the third average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity. In some embodiments, the first average porosity is less than 20% of the third average porosity, and the third average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity. In some embodiments, the first average porosity is less than 15% of the third average porosity, and the third average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity. In some embodiments, the first average porosity is less than 10% of the third average porosity, and the third average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity.In some embodiments, the first average porosity is less than 5% of the third average porosity, and the third average porosity is less than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5% of the second average porosity.

[0045] density As used herein, a construction material is provided, comprising: (a) a first surface; (b) a second surface substantially opposite the first surface; (c) one or more walls between and connecting the first and second surfaces; (d) a body encapsulated by the first surface, the second surface, and the one or more walls, the body comprising a plurality of aggregate particles; (e) calcium carbonate; and (f) at least one biological organism or enzyme that produces at least a portion of the calcium carbonate formed between at least two or more members of the plurality of aggregate particles; or 2) the average final density of the construction material is from about 1.8 g / cc to about 2.7 g / cc, or 3) the average percentage of voids in the green density is from about 25% to about 46%, or 4) the average percentage of voids filled in the finished product (e.g., average percentage of CaCO produced) is from about 5% to about 25%, or 5) any combination thereof. As used herein, the unit "g / cc" refers to the density unit grams per cubic centimeter (g / cm). 3 The percentage of voids in a portion of a construction material can correspond to the average porosity for that portion of the construction material.

[0046] As used herein, the term "green density" generally refers to the density of a construction material before sintering. The term "green density" may refer to wet green density, which may include the density of a pressed unit when pressed, or dry green density, which may include the density of a pressed unit that has been thoroughly dried out.

[0047] As used herein, the term "final density" generally refers to the density of a construction material after sintering. In some embodiments, the average green density is about 1.5 g / cc to about 1.8 g / cc, about 1.6 g / cc to about 1.9 g / cc, about 1.7 g / cc to about 2.0 g / cc, about 1.8 g / cc to about 2.1 g / cc, about 1.9 g / cc to about 2.2 g / cc, about 2.0 g / cc to about 2.3 g / cc, or about 2.1 g / cc to about 2.4 g / cc. In some embodiments, the average green density is about 1.7 g / cc to about 2.0 g / cc. In some embodiments, the average green density is about 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, or 2.4 g / cc. In some embodiments, the average final density is 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, or about 2.6 g / cc to about 2.7 g / cc. In some embodiments, the average final density is about 2.0 g / cc to about 2.1 g / cc. In some embodiments, the average final density is about 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, or 2.7 g / cc. In some embodiments, the average percentage of voids in the green density is about 25% to about 28%, about 28% to about 31%, about 31% to about 34%, about 34% to about 37%, about 37% to about 40%, about 40% to about 43%, or about 43% to about 46%. In some embodiments, the average percentage of voids in the green density is about 30% to about 42%. In some embodiments, the average percentage of voids in the green density is about 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 31%, 42%, 43%, 44%, 45%, 46%, or 47%. In some embodiments, the average percentage of CaC0 produced is between about 5% and about 10%, between about 10% and about 15%, between about 15% and about 20%, or between about 20% and about 25%. In some embodiments, the average percentage of CaC0 produced is between 10% and about 23%.In some embodiments, the average percentage of CaC0 produced is about 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, or 25%.

[0048] homogeneity (c) one or more walls between and connecting the first and second surfaces; (d) a body encapsulated by the first surface, the second surface, and the one or more walls, the body comprising a plurality of aggregate particles; (e) calcium carbonate; and (f) at least one biological organism or enzyme that produces at least a portion of the calcium carbonate formed between at least two members of the plurality of aggregate particles, wherein the homogeneity of the formed biocement is assessed by a compressive strength profile from the top to the bottom surface, or from a percentage calcium carbonate distribution profile from the top to the bottom surface, or from comparing images generated from SEM / EDX (scanning electron microscopy and energy dispersive X-ray spectroscopy) with the compressive strength of selected layers away from the top or bottom surface.

[0049] In some embodiments, by comparing samples from passing and failing units based on compressive strength, passing units contain a higher percentage of calcium carbonate, and thereby a higher percentage of biocement (or biologically formed calcium carbonate). In some embodiments, the distribution of biocement is more homogeneous or integrated (e.g., less variation between layers at various depths from the top surface) in passing units than in failing units. In some embodiments, the distribution of biocement is assessed by the percentage of calcium carbonate, or the percentage of calcium carbonate created, or the percentage of voids after sintering. In some embodiments, the sintering temperature is lower for making construction materials of the present disclosure containing biocement than for making traditional construction materials that are substantially free of biocement (e.g., construction materials containing no more than 5%, 4%, 3%, 2%, or 1% biocement in calcium carbonate).

[0050] Material / composition Construction materials according to the present disclosure may be substantially homogeneous. In some embodiments, construction materials according to the present disclosure and methods provided herein may be substantially continuous. In some embodiments, the construction material is substantially homogeneous. In some embodiments, the construction material is substantially porous.

[0051] The plurality of aggregate particles may comprise any type of natural rock or stone, glass, fiberglass, wood, biomass, paper, metal, plastic, polymer, rubber, imitation rubber, vinyl, mineral, rock or stone imitation, recycled material such as recycled brick, concrete, stone, mine tailings and slag, scrubber waste, and / or combinations thereof. The plurality of aggregate particles may be of any size, including a mixture of sizes, provided that such aggregates are smaller in size than the resulting structure. The plurality of aggregate particles may comprise particles of 10 mm or less, 5 mm or less, 1 mm or less, 0.5 mm or less, or combinations thereof. Mesh sizes can be as desired, including, but not limited to, very fine (any number between 32 and 300 standard meshes, inclusive), fine (any number between 10 and 32 standard meshes, inclusive), medium (less than 10 standard meshes, inclusive, and all mesh numbers therein), and coarse (greater than or equal to 2 mm), and combinations thereof. The particles can be of almost any shape, including, for example, round or rounded, ellipsoidal, spherical (S grade), square, rectangular, tetrahedral, pentahedral, polyhedral, fibrous, sawdust, angular, elongated, acicular, pointed, flat, flaky, cylindrical, spongy, cubic, cuboidal, and combinations and variations thereof. If desired or necessary, the aggregate particles can be roughened to create cracks and interstices on the particle surface.

[0052] Aggregate materials may include rock (e.g., fines), sand, glass, wood, paper, metal, plastic, polymer, mineral, manufacturing or processing waste material such as ash, carbon, or wood residues, any of which may be crushed or used whole, or combinations thereof.

[0053] Aggregate materials may include organic or inorganic materials such as sand, rock, glass (e.g., porobel), wood, paper, metal, plastic, polymer, mineral, recycled material, or combinations thereof. Aggregate particles may include beads, grains, rods, strands, fibers, flakes, crystals, crushed or crushed material, or combinations thereof.

[0054] The aggregate particles may have a diameter (e.g., actual, average, or effective diameter) of about 50 mm or less, preferably about 25 mm or less, preferably about 20 mm or less, preferably about 10 mm or less, and preferably about 5 mm or less. In some embodiments, the aggregate material may be about 1 mm or less and about 0.5 mm or less, about 0.1 mm or less and about 50 μm or less. Particle sizes may include about 10 μm to about 1 mm, about 100 μm to about 0.5 mm, about 200 μm to about 1 mm, about 1 μm to about 200 μm, about 10 nm to about 1 μm, and about 10 nm to about 40 nm, and various combinations thereof. The aggregate particles may be composed predominantly of fine particles less than 5 mm in diameter (e.g., less than or about 4 mm, less than or about 3 mm, less than or about 2 mm, or less than or about 1 mm).

[0055] The aggregate particles may be characterized by a fine size, which may be equal to or less than 250 microns, equal to or less than 200 microns, equal to or less than 150 microns, or equal to or less than 100 microns (reference examples include beach sand micron size=700, fine sand micron size=250; Portland cement micron size=74; silt micron size=44; smoke micron size=2).

[0056] In some embodiments, aggregates containing larger particles, e.g., centimeter- or millimeter-sized particles, such as gravel, stone, or crushed rock, may be used. In some embodiments, the particle size range may range from 1 μm or 10 μm to 5 cm or larger. In some embodiments, the granular starting material may consist of, or at least essentially consist of, small particles, particularly μm-scale particles. In other words, the particles may be sized between or within a range of 1 μm and 1 mm (1000 μm), e.g., between or within 100-1000 μm or 100-500 μm, e.g., between or within 200-400 μm or 200-300 μm. However, larger-sized particles may be, for example, between 1 mm and 2 mm, or may have a wider range of sizes, e.g., between 100 μm and 2 mm.

[0057] The cross-linked calcium carbonate may bond to or encapsulate individual aggregate particles to create bridges between the aggregate particles. The cross-linked calcium carbonate may be formed from the reaction of calcium with carbonate ions. An enzyme or a biological organism and a reagent that produces the enzyme may be added together or separately to result in the formation of calcium carbonate. The calcium carbonate may be precipitated calcium carbonate. In some embodiments, the cross-linked calcium carbonate may be crystalline, such as cross-linked calcium carbonate crystals. In some embodiments, the cross-linked calcium carbonate crystals are regular, pseudocrystalline, or amorphous. In some embodiments, the cross-linked calcium carbonate crystals are macroscopically regular and include trigonal, orthorhombic, or hexagonal crystal structures.

[0058] The at least one biological organism or enzyme may comprise a urease-producing microorganism selected from the group consisting of Sporosarcina pasteurii, Sporosarcina ureae, Proteus vulgaris, Bacillus sphaericus, Myxococcus xanthus, Proteus mirabilis, Bacillus megaterium, Helicobacter pylori, and combinations of two or more thereof.

[0059] The at least one biological organism or enzyme may comprise an enzyme-producing biological organism. The enzyme-producing biological organism may be an acid-producing microorganism. The acid-producing microorganism may be selected from the group consisting of: Variovorax, Klebsiella, Pseudomonas, Bacillus, Exiguobacterium, Microbacterium, Curtobacterium, Rathayibacter, CellFimi2, Streptomyces, Raoultella, B. pumilus, B. safanensis, B. simplex, B. licheniformis, and combinations thereof.

[0060] In some embodiments, the construction material may further comprise a binder. The binder may be generated through a biological mechanism (such as an enzymatic process) that adheres or encapsulates aggregate particles. In some embodiments, the binder may be a biological organism or an enzyme. The biological organism may be any urease-producing organism, acid-producing organism, or carbonic anhydrase-producing organism. The enzyme may be urease or carbonic anhydrase.

[0061] Physical Properties of Construction Materials In some embodiments, the construction material has a compressive strength of about 900 psi to about 3,500 psi. In some embodiments, the construction material has a compressive strength of about 900 psi to about 1,000 psi, about 900 psi to about 1,100 psi, about 900 psi to about 1,200 psi, about 900 psi to about 1,300 psi, about 900 psi to about 1,400 psi, about 900 psi to about 1,600 psi, about 900 psi to about 1,800 psi, about 900 psi to about 2,000 psi, about 900 psi to about 2,500 psi, about 900 psi to about 3,000 psi, about 900 psi to about 3,500 psi, about 1,000 psi to about 1,100 psi, about 1,000 psi to about 1,000 psi. 0 psi to about 1,200 psi, about 1,000 psi to about 1,300 psi, about 1,000 psi to about 1,400 psi, about 1,000 psi to about 1,600 psi, about 1,000 psi to about 1,800 psi, about 1,000 psi to about 2,000 psi, about 1,000 psi to about 2,500 psi, about 1,000 psi to about 3,000 psi, about 1,000 psi to about 3,500 psi, about 1,100 psi to about 1,200 psi, about 1,100 psi to about 1,300 psi, about 1,100 psi to about 1,400 psi, about 1,1 00psi to about 1,600psi, about 1,100psi to about 1,800psi, about 1,100psi to about 2,000psi, about 1,100psi to about 2,500psi, about 1,100psi to about 3,000psi, about 1,100psi to about 3,500psi, about 1,200psi to about 1,300psi, about 1,200psi to about 1,400psi, about 1,200psi to about 1,600psi, about 1,200psi to about 1,800psi, about 1,200psi to about 2,000psi, about 1,200psi to about 2,500psi, about 1, 200 psi to about 3,000 psi, about 1,200 psi to about 3,500 psi, about 1,300 psi to about 1,400 psi, about 1,300 psi to about 1,600 psi, about 1,300 psi to about 1,800 psi, about 1,300 psi to about 2,000 psi, about 1,300 psi to about 2,500 psi, about 1,300 psi to about 3,000 psi, about 1,300 psi to about 3,500 psi, about 1,400 psi to about 1,600 psi, about 1,400 psi to about 1,800 psi, about 1,400 psi to about 2,000 psi, about 1,400psi to about 2,500psi, about 1,400psi to about 3,000psi, about 1,400psi to about 3,500psi, about 1,600psi to about 1,800psi, about 1,600psi to about 2,000psi, about 1,600psi to about 2,500psi, about 1,600psi to about 3,000psi, about 1,600psi to about 3,500psi, about 1,800psi to about 2,000psi, about 1,800 The compressive strength is from about 2,500 psi to about 2,500 psi, from about 1,800 psi to about 3,000 psi, from about 1,800 psi to about 3,500 psi, from about 2,000 psi to about 2,500 psi, from about 2,000 psi to about 3,000 psi, from about 2,000 psi to about 3,500 psi, from about 2,500 psi to about 3,000 psi, from about 2,500 psi to about 3,500 psi, or from about 3,000 psi to about 3,500 psi. In some embodiments, the construction material has a compressive strength of about 900 psi, about 1,000 psi, about 1,100 psi, about 1,200 psi, about 1,300 psi, about 1,400 psi, about 1,600 psi, about 1,800 psi, about 2,000 psi, about 2,500 psi, about 3,000 psi, or about 3,500 psi. In some embodiments, the construction material has a compressive strength of at least about 900 psi, about 1,000 psi, about 1,100 psi, about 1,200 psi, about 1,300 psi, about 1,400 psi, about 1,600 psi, about 1,800 psi, about 2,000 psi, about 2,500 psi, or about 3,000 psi. In some embodiments, the construction material has a compressive strength of less than or equal to about 1,000 psi, about 1,100 psi, about 1,200 psi, about 1,300 psi, about 1,400 psi, about 1,600 psi, about 1,800 psi, about 2,000 psi, about 2,500 psi, about 3,000 psi, or about 3,500 psi.

[0062] In some embodiments, the mass of crosslinked and non-crosslinked calcium carbonate in the construction material is from about 0.01% to about 20% by weight. In some embodiments, the mass of calcium carbonate in the construction material is from about 0.01% to about 0.1% by weight, from about 0.01% to about 0.5% by weight, from about 0.01% to about 1% by weight, from about 0.01% to about 2% by weight, from about 0.01% to about 3% by weight, from about 0.01% to about 4% by weight, from about 0.01% to about 5% by weight, from about 0.01% to about 7% by weight, from about 0.01% to about 10% by weight, from about 0.01% to about 15% by weight, from about 0.01% to about 20% by weight, from about 0.1% to about 0.5% by weight, from about 0.1% to about 1% by weight, or from about 0. 1% to about 2% by weight, about 0.1% to about 3% by weight, about 0.1% to about 4% by weight, about 0.1% to about 5% by weight, about 0.1% to about 7% by weight, about 0.1% to about 10% by weight, about 0.1% to about 15% by weight, about 0.1% to about 20% by weight, about 0.5% by weight Amount% ~ about 1% by weight, about 0.5% by weight - about 2% by weight, about 0.5% by weight - about 3% by weight, about 0.5% by weight - about 4% by weight, about 0.5% by weight - about 5% by weight, about 0.5% by weight - about 7% by weight, about 0.5% by weight - about 10% by weight, about 0.5% by weight - about 15% by weight, about 0.5% by weight - About 20% by weight, about 1% to about 2% by weight, about 1% to about 3% by weight, about 1% to about 4% by weight, about 1% to about 5% by weight, about 1% to about 7% by weight, about 1% to about 10% by weight, about 1% to about 15% by weight, about 1% to about 20% by weight, about 2% to about 3% by weight %, about 2% to about 4%, about 2% to about 5%, about 2% to about 7%, about 2% to about 10%, about 2% to about 15%, about 2% to about 20%, about 3% to about 4%, about 3% to about 5%, about 3% to about 7%, about 3% by weight % to about 10% by weight, about 3% to about 15% by weight, about 3% to about 20% by weight, about 4% to about 5% by weight, about 4% to about 7% by weight, about 4% to about 10% by weight, about 4% to about 15% by weight, about 4% to about 20% by weight, about 5% to about 7% by weight, about 5% to about 10% by weight, about 5% to about 15% by weight, about 5% to about 20% by weight, about 7% to about 10% by weight, about 7% to about 15% by weight, about 7% to about 20% by weight, about 10% to about 15% by weight, about 10% to about 20% by weight, or about 15% to about 20% by weight.In some embodiments, the mass of calcium carbonate in the construction material is about 0.01%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 7%, about 10%, about 15%, or about 20% by weight. In some embodiments, the mass of calcium carbonate in the construction material is at least about 0.01%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 7%, about 10%, or about 15% by weight. In some embodiments, the mass of calcium carbonate in the construction material is no more than about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 7%, about 10%, about 15%, or about 20% by weight.

[0063] System for generating construction materials Described herein is a system for a plurality of frameworks, each of the plurality of frameworks including a bottom and one or more walls. In some embodiments, the bottom and the one or more walls together define a space. In some embodiments, the system may further include an inlet or source configured to add a cementing reagent to the space. In some embodiments, the system may further include an outlet configured to remove a mobile phase from the space, the mobile phase comprising: (b) a depleted cementing reagent; a heat exchange system in thermal communication with the plurality of frameworks; and (c) a controller in communication with the inlet, the outlet, and the heat exchange system, the controller configured to control a duty cycle of the system. The duty cycle includes adding the cementing reagent to the space, removing the mobile phase from the space, and increasing the temperature of the bottom above the temperature of the cementing reagent at the inlet during the addition of the cementing reagent.

[0064] The heat exchange system may be programmed to introduce a temperature gradient along the plurality of frameworks. In some embodiments, the heat exchange system may be programmed to introduce and / or maintain a constant temperature along the plurality of frameworks. In some embodiments, the heat exchange system may be programmed to introduce distinct temperatures along various regions along the plurality of frameworks. As used herein, a heat exchange system may include a heat exchanger. A controller configured to control the duty cycle of the system may be a controller or an electronic system.

[0065] In some embodiments, the duty cycle allows for controlled directional crystal growth of calcium carbonate to form crosslinked calcium carbonate. In some embodiments, the duty cycle further comprises cooling / heating the bottom and / or one or more walls after completing the addition of the cementing reagent. In some embodiments, the duty cycle further comprises cooling / heating the inlet during and / or after adding the cementing reagent. In some embodiments, the duty cycle further comprises adding air, oxygen, or ozone to the space or the top of the space; and / or removing air, oxygen, or ozone from the space or the top of the space. In some embodiments, the duty cycle further comprises irradiating the space using ultraviolet light. In some embodiments, the duty cycle further comprises vibrating the plurality of frameworks.

[0066] In some embodiments, hydroponic methods are used to produce construction materials containing biocement. In some embodiments, the multiple frameworks are also referred to as multiple reaction chambers. In some embodiments, each framework or reaction chamber is charged with aggregate particles, either preheated or not. In some embodiments, a first feed-on solution / liquid is added to each framework / reaction chamber in a first bath during a "feed-on" state / cycle of the duty cycle. In some embodiments, the temperature of the feed-on solution / liquid is controlled. In some embodiments, no feed-on solution / liquid is provided to each framework / reaction chamber during a "feed-off" state / cycle of the duty cycle. In some embodiments, the bottom of the framework / reaction chamber is heated by a heat exchange device or heater. In some embodiments, the feed-on solution / fluid is added from the top (or from an upper opening of the framework / reaction chamber or an inlet near the top of the framework / reaction chamber). In some embodiments, either near or after the end of the feed-off state / cycle, the remaining feed-on solution / fluid is substantially drained before the start of the next cycle (e.g., a subsequent feed-on cycle / state).

[0067] How to Produce Construction Materials The manufacturing methods described herein can be used to make any of the construction materials described herein. The method may include adding a plurality of aggregate particles and at least one biological organism or enzyme to a framework, thus forming a framed plurality of aggregate particles. The aggregate particles may include at least one surface and a body encapsulated by the at least one surface, with the at least one biological organism or enzyme being within at least the body. A cementing reagent may be supplied to the framed plurality of aggregate particles. The method may include (i) controlling a first temperature of the body relative to a second temperature of the supplied cementing reagent and / or a third temperature above the framed plurality of aggregate particles. The method may include forming crosslinked calcium carbonate crystals between at least two members of the framed plurality of aggregate particles and non-crosslinked calcium carbonate crystals from a starting material generated from the at least one biological organism or enzyme.

[0068] In some embodiments, the process for producing a construction material may be a hydroponic process. In some embodiments, during the hydroponic process, each of a plurality of pressurized aggregate units is supplied with a calcium ion source chemical and a carbonate ion source chemical to form biocement (or calcium carbonate formed from biologically generated calcium ions and / or carbonate ions), which is biologically formed calcium carbonate. In some embodiments, this biocement (calcium carbonate) formation process may occur in the voids of the pressurized aggregate units. In some embodiments, the calcium ions are biologically formed. In some embodiments, the carbonate ions are biologically formed. In some embodiments, both the calcium ions and the carbonate ions are biologically formed. As used herein, the term "biologically formed" generally refers to the formation of a product from a starting material by a biological agent. In some embodiments, the biological agent may be one or more enzymes, one or more microorganisms, or a combination thereof. In some embodiments, this biocement (calcium carbonate) formation process may bridge gaps between aggregate particles within each of a plurality of pressurized aggregate units. In some embodiments, the hydroponic process includes some or all of the steps of aggregate blend preparation, germination, pressing, drying, feeding, odor removal, and finishing. In some embodiments, each of the steps of aggregate blend preparation, germination, pressing, drying, feeding, odor removal, and finishing is performed under controlled parameters. In some embodiments, the formed product may be evaluated based on parameters including, but not limited to, compressive strength, flexural strength, absorption, and sustained freeze-thaw cycling.

[0069] In some embodiments, the duty cycle includes a feed process that provides reagents to the framework. In some embodiments, the feed process includes a duty cycle that includes multiple cycles, with independent parameters including feed-on and feed-off times per cycle and a total number of cycles. In some embodiments, the duty cycle of the feed process includes a first bath and multiple subsequent baths. In some embodiments, the first bath includes a first feed-on time that is about 80 seconds to about 120 seconds. In some embodiments, the first feed-on time is about 80 seconds to about 85 seconds, about 85 seconds to about 90 seconds, about 90 seconds to about 95 seconds, about 95 seconds to about 100 seconds, about 100 seconds to about 105 seconds, about 105 seconds to about 110 seconds, about 110 seconds to about 115 seconds, or about 115 seconds to about 120 seconds. In some embodiments, the first feed-on time is about 80, 85, 90, 95, 100, 105, 110, 115, or 120 seconds. In some embodiments, the first feed-on time is about 100 seconds. In some embodiments, the first bath includes a first feed-off time that is about 800 seconds to about 1,000 seconds. In some embodiments, the first feed-off time is about 800 seconds to about 820 seconds, about 820 seconds to about 840 seconds, about 840 seconds to about 860 seconds, about 860 seconds to about 880 seconds, about 880 seconds to about 900 seconds, about 900 seconds to about 920 seconds, about 920 seconds to about 940 seconds, about 940 seconds to about 960 seconds, about 960 seconds to about 980 seconds, or about 980 seconds to about 1,000 seconds. In some embodiments, the first feed-on time is about 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, or 1,000 seconds. In some embodiments, the first feed-off time is about 900 seconds.

[0070] In some embodiments, each of the multiple subsequent baths independently comprises a subsequent feed-on time that is about 80 seconds to about 120 seconds. In some embodiments, the subsequent feed-on times are independently about 80 seconds to about 85 seconds, about 85 seconds to about 90 seconds, about 90 seconds to about 95 seconds, about 95 seconds to about 100 seconds, about 100 seconds to about 105 seconds, about 105 seconds to about 110 seconds, about 110 seconds to about 115 seconds, or about 115 seconds to about 120 seconds. In some embodiments, the subsequent feed-on times are independently about 80, 85, 90, 95, 100, 105, 115, or 120 seconds. In some embodiments, the subsequent feed-on times are independently about 100 seconds. In some embodiments, each of the multiple subsequent baths independently comprises a subsequent feed-off time that is about 400 seconds to about 600 seconds. In some embodiments, subsequent feed-off times are independently about 400 seconds to about 420 seconds, about 420 seconds to about 440 seconds, about 440 seconds to about 460 seconds, about 460 seconds to about 480 seconds, about 480 seconds to about 500 seconds, about 500 seconds to about 520 seconds, about 520 seconds to about 540 seconds, about 540 seconds to about 560 seconds, about 560 seconds to about 580 seconds, or about 580 seconds to about 600 seconds. In some embodiments, subsequent feed-on times are independently about 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, or 600 seconds. In some embodiments, subsequent feed-off times are independently about 500 seconds. In some embodiments, the total number of cycles is about 15 to about 40. In some embodiments, the total number of cycles is about 15 to about 22, about 17 to about 24, about 19 to about 26, about 21 to about 28, about 23 to about 30, about 25 to about 32, about 27 to about 34, about 29 to about 36, about 31 to about 38, or about 33 to about 40. In some embodiments, the total number of cycles is about 23 to about 30. In some embodiments, the total number of cycles is about 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, or 40.

[0071] In some embodiments, the feed-on solution / fluid comprises urea and a calcium salt (e.g., calcium chloride or other calcium 2+In some embodiments, the concentration of urea is about 180 mM to about 330 mM. In some embodiments, the concentration of urea 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 urea concentration is about 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, or 330 mM. In some embodiments, the urea concentration is about 230 mM. In some embodiments, the urea concentration is about 240 mM. In some embodiments, the urea concentration is about 240 mM. In some embodiments, the urea concentration is about 260 mM. In some embodiments, the urea concentration is about 270 mM. In some embodiments, the urea concentration is about 280 mM. In some embodiments, the calcium chloride concentration is 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 calcium chloride concentration is about 260 mM. In some embodiments, the calcium chloride concentration is about 270 mM. In some embodiments, the calcium chloride concentration is about 280 mM. In some embodiments, the urea concentration is about the same as the calcium chloride concentration. In some embodiments, the urea concentration is different from the calcium chloride concentration.

[0072] In some embodiments, the act of controlling a first temperature of the body comprises heating / cooling a bottom of the framework. In some embodiments, the act of controlling a first temperature of the body comprises heating a bottom of the framework. In some embodiments, the act of controlling a first temperature of the body comprises heating / cooling a dispensed cementing reagent. In some embodiments, the act of controlling a first temperature of the body comprises cooling a dispensed cementing reagent. In some embodiments, the act of controlling a first temperature comprises heating / cooling a solution phase above the plurality of aggregate particles encased in the frame.

[0073] In some embodiments, the duty cycle may include controlled temperature ranges for multiple components. In some embodiments, the temperature-controlled components include a first temperature of each framework / body / reaction chamber where the pressurized aggregate is bonded by the biocement, a second temperature of the feed-on solution / liquid, and / or the difference between the first and second temperatures. In some embodiments, the first temperature (i.e., the temperature of each framework / body / reaction chamber) is about 28°C to about 38°C. In some embodiments, the first temperature is about 28°C to about 30°C, about 30°C to about 32°C, about 32°C to about 34°C, about 34°C to about 36°C, or about 36°C to about 38°C. In some embodiments, the first temperature is about 32°C to about 34°C. In some embodiments, the first temperature is about 28°C, 29°C, 30°C, 31°C, 32°C, 33°C, 34°C, 35°C, 36°C, 37°C, or 38°C. In some embodiments, the second temperature (i.e., the temperature of the feed-on solution / fluid) is about 26°C to about 37°C. In some embodiments, the second temperature is about 26°C to about 27°C, about 27°C to about 28°C, about 28°C to about 29°C, about 29°C to about 30°C, about 30°C to about 31°C, about 31°C to about 32°C, about 32°C to about 33°C, about 33°C to about 34°C, about 34°C to about 35°C, about 35°C to about 36°C, or about 36°C to about 37°C. In some embodiments, the second temperature is about 30°C to about 31°C. In some embodiments, the second temperature is about 26°C, 27°C, 28°C, 29°C, 30°C, 31°C, 32°C, 33°C, 34°C, 35°C, 36°C, or 37°C. In some embodiments, the difference between the first and second temperatures is about 1°C, about 2°C, or about 3°C. In some embodiments, the difference between the first and second temperatures is about 1°C. In some embodiments, the difference between the first and second temperatures is about 2°C. In some embodiments, the difference between the first and second temperatures is about 3°C. In some embodiments, the first temperature is about 36°C and the second temperature is about 35°C. In some embodiments, the first temperature is about 36°C and the second temperature is about 34°C. In some embodiments, the first temperature is about 36°C and the second temperature is about 33°C. In some embodiments, the first temperature is about 35°C and the second temperature is about 34°C. In some embodiments, the first temperature is about 35°C and the second temperature is about 33°C.In some embodiments, the first temperature is about 35°C and the second temperature is about 32°C. In some embodiments, the first temperature is about 34°C and the second temperature is about 33°C. In some embodiments, the first temperature is about 34°C and the second temperature is about 32°C. In some embodiments, the first temperature is about 34°C and the second temperature is about 31°C. In some embodiments, the first temperature is about 33°C and the second temperature is about 32°C. In some embodiments, the first temperature is about 33°C and the second temperature is about 31°C. In some embodiments, the first temperature is about 33°C and the second temperature is about 30°C. In some embodiments, the first temperature is about 32°C and the second temperature is about 31°C. In some embodiments, the first temperature is about 32°C and the second temperature is about 30°C. In some embodiments, the first temperature is about 32°C and the second temperature is about 30°C. In some embodiments, the first temperature is about 32°C and the second temperature is about 29°C. In some embodiments, the first temperature is about 31°C and the second temperature is about 30°C. In some embodiments, the first temperature is about 31°C and the second temperature is about 29°C. In some embodiments, the first temperature is about 31°C and the second temperature is about 28°C. In some embodiments, the first temperature is about 30°C and the second temperature is about 29°C. In some embodiments, the first temperature is about 30°C and the second temperature is about 28°C. In some embodiments, the first temperature is about 30°C and the second temperature is about 27°C. In some embodiments, the first temperature is about 29°C and the second temperature is about 28°C. In some embodiments, the first temperature is about 29°C and the second temperature is about 27°C. In some embodiments, the first temperature is about 29°C and the second temperature is about 26°C.

[0074] In some embodiments, the method may further include adding air, oxygen, or ozone to the top of the framework. In some embodiments, the method may further include removing air, oxygen, or ozone from the top of the framework.

[0075] In some embodiments, the method may further include hardening the framed plurality of aggregate particles. In some embodiments, the act of hardening the framed plurality of aggregate particles includes irradiating the framework with ultraviolet light. In some embodiments, the method may further include vibrating the plurality of frameworks. In some embodiments, the method may further include removing a mobile phase from the framework, the mobile phase including the depleted cementing reagent. In some embodiments, the method may further include controlling a growth time of at least one biological organism or enzyme in the body before supplying a dose of calcium ions to the framed plurality of aggregate particles. In some embodiments, the method may further include controlling a concentration and / or a supply rate of the dose of calcium to the framed plurality of aggregate particles.

[0076] In some embodiments, the aggregate particles can be roughened by mixing the particles together in a mixer or blender with sufficient force to create cracks and crevices on the particle surface, by adding ball bearings or another material to the aggregate particles that has a hardness equal to or greater than the particle itself, by passing the particles through a roughening agent such as sand, steel, or industrial diamond, or another roughening agent known to those skilled in the art, or a combination thereof.

[0077] The temperature, humidity, and / or pH of the framed plurality of aggregate particles can be monitored and controlled during the reaction to form the building material. The act of forming crosslinked calcium carbonate crystals between at least two members of the framed plurality of aggregate particles can include at least one biological organism or enzyme, further including urease or cells of a urease-producing microorganism. The act of forming crosslinked calcium carbonate crystals between at least two members of the framed plurality of aggregate particles can include acid-producing enzymes or cells of an acid-producing microorganism and / or cells of a carbonic anhydrase or carbonic anhydrase-producing microorganism.

[0078] Urease-producing microorganisms can include, but are not limited to, Sporosarcina pasteurii, Sporosarcina ureae, Proteus vulgaris, Bacillus spericus, Myxococcus xanthus, Proteus mirabilis, Bacillus megaterium, Helicobacter pylori, and combinations of two or more thereof. In some embodiments, the cells comprise spores. The biocementation reagent can further comprise nutrients that promote microbial growth or enzymatic activity. In some embodiments, the nutrients include one or more of salts, amino acids, proteins, peptides, carbohydrates, sugars, polysaccharides, fatty acids, oils, vitamins, and minerals.

[0079] The cementing reagent may include a calcium source. The cementing reagent may include a urea source. The cementing reagent includes calcium carbonate. The biocementing reagent includes calcium chloride. The cementing reagent may include cells of a urease-producing microorganism. In some embodiments, the urea-producing microorganism is selected from the group consisting of: Pseudomonas spp., Delaya avenusta, Thiosphaera pantotropha, Pseudomonas stutzen, Fragilaria crotonensis, Pseudoalteromonas spp., Pseudoalteromonas haloplanktis, Halomonas venusta, Pseudomonas balearica, Pseudomonas stutzeri, Bacillus megaterium, Exiguobacterium auranticum, and the like. aurantiacum, Pseudoalteromonas aliena, Pseudoalteromonas luteoviolacea, E. coli, and variants, serotypes, mutations, recombinant forms, and combinations thereof. In some embodiments, the acid-producing microorganism is selected from the group consisting of: Variovorax, Klebsiella, Pseudomonas, Bacillus, Exiguobacterium, Microbacterium, Curtobacterium, Raceibacter, Serfimi2, Streptomyces, Raoultella, B. pumilus, B. safanensis, B. simuplex, B. licheniformis, and combinations thereof.

[0080] In some embodiments, the acid produced by the acid-producing enzymes of the cells of the acid-producing microorganism is a carboxylic acid. In some embodiments, the acid produced by the acid-producing enzymes of the cells of the acid-producing microorganism is acetic acid, formic acid, propionic acid, butyric acid, gluconic acid, succinic acid, lactic acid, or citric acid. In some embodiments, the method further comprises compacting the mixture to reduce the average linear distance between adjacent aggregate particles by at least about 25%. In some embodiments, the method further comprises compacting the mixture to produce an absolute packing efficiency of the aggregate particles of at least about 50%.

[0081] In some embodiments, the method further includes compacting the mixture by placing the mixture in a vibrating press and applying pressure and vibration to reduce the volume of void spaces between the aggregate particles. In some embodiments, the vibrating motor of the press operates at a rotational speed of about 100 RPM to about 7200 RPM. In some embodiments, the vibrating motor of the press operates at a duty cycle of 0.01% to about 100%. In some embodiments, the vibration and pressure are applied simultaneously. In some embodiments, the vibration and pressure are applied alternately. In some embodiments, the resulting building material comprises at least about 2% calcium carbonate by weight. In some embodiments, the finished building material comprises no more than about 20% calcium carbonate by weight.

[0082] FIG. 1A illustrates one embodiment of a form 10. In some cases, form 10 may comprise a temporary structure, mold, or container for forming a plurality of aggregate particles. Form 10 contains aggregate material, such as sand or other solid objects of a selected size, while the aggregate is treated with a feed-on solution containing microbial organisms (e.g., enzyme-producing bacteria) and / or enzymes (e.g., urease) and / or calcium ions and / or urea and / or other nutrients or components. In one example, urease is formed by exposing a quantity of urea to enzyme-producing bacteria, such as Sporosarcina pasteurii. Form 10 includes four vertical walls 12, a top panel 14, and a bottom panel 16, all connected to form a cavity 30 therebetween. The top panel 14 includes multiple inlets 18 for feeding the feed-on solution (influent) into cavity 30. The bottom panel includes multiple outlets 20 for allowing effluent to exit cavity 30.

[0083] In some embodiments, the feed-on solution may be delivered to the cavity 30 or to the material within the cavity 30 via a feed source or feed distribution system. The feed distribution system may utilize a spray or drip mechanism to distribute the feed-on solution.

[0084] The cavity 30 is adapted to receive loose aggregate pieces, such as sand. Some, if not all, of the panels are removable to facilitate removal of the contents (e.g., bricks) from the cavity 30. The vertical walls 12, or at least their interior surfaces, may be made of a non-reactive, non-porous material, such as a cast or extruded acrylic resin. Additional sensors (e.g., temperature sensors, oxygen sensors, calcium ion sensors, carbon dioxide sensors, cameras, etc.) may be installed to monitor conditions in or around the cavity 30. The addition or discharge of feed-on solution can be controlled based in part on data obtained by the sensors. The condition and / or rate at which the feed-on solution is introduced can be controlled in part on data obtained by the sensors.

[0085] To begin the process, aggregate material is layered or partially placed within the cavity 30. The aggregate material is filtered through an aggregate filter to select the size of the aggregate to be fed into the cavity 30. The top panel 14 is then placed on top of the aggregate material, sealing the cavity 30. A feed-on solution is introduced into the cavity through multiple inlets 18. The composition of the feed-on solution can be varied over time. The temperature of the feed-on solution before entering the cavity 30 can be controlled by a heat exchange module to heat or cool the feed-on solution to a desired temperature. The rate at which the feed-on solution is introduced is controlled by a pump or other mechanism. The outlet 20 is closed or partially closed when the feed-on solution is introduced into the cavity 30. When the multiple outlets 20 are open, effluent can be discharged out of the cavity 30. An optional mechanical stirrer can be installed within the cavity 30, or a shaker can be used to agitate the contents within the cavity 30. The supply and discharge of the feed-on solution can be repeated multiple times. The length of time between supply and discharge of the feed-on solution can vary, including, but not limited to, one minute, ten minutes, several tens of minutes, one hour, several hours, half a day, one day, one and a half days, two days, or other lengths of time. Additional inlets and / or outlets may be available on the framework 10 around the body (e.g., on the vertical walls 12).

[0086] After the final flow of the feed-on solution as a bath on the aggregate material, any remaining solution in the cavity 30 is removed. Optionally, a wash solution is introduced into the cavity 30 to rinse the formed product (e.g., brick) and / or kill any remaining organisms. Optionally, air or inert air is introduced through the inlet, blown into the cavity 30, and exits through the outlet 20. This air treatment can be added during the incubation of the feed-on solution / bath to blow off or remove any coating on the top surface. Such a coating on the top surface may block pores through which the feed-on solution can enter the body / interior of the aggregate / brick. At the end of the bath treatment, the formed product is then removed from the cavity 30 and examined / stored. For example, layers having different depths from the top surface of the brick can be prepared and analyzed by scanning electron microscopy (SEM) or other analytical methods. For example, the brick can be cut at different depths from the top surface of the brick. Properties such as the chemical identity of the aggregate particles within the brick, porosity, water absorption capacity, size distribution, and mechanical strength of each layer can be obtained and compared and correlated with each other and with the process conditions. Thus, the bath treatment parameters and / or the components of the feed-on solution can be adjusted to improve the properties of the formed product (e.g., brick).

[0087] As shown in FIG. 1A, the vertical walls 12 extend in a first direction (e.g., the Z direction), the top panel 14 extends in a second direction perpendicular to the first direction, and the bottom panel 16 extends in a second direction (e.g., the X direction).

[0088] FIG. 1B illustrates one embodiment of a cross-sectional view of a construction material 68. The construction material 68 may include a plurality of aggregate particles. The construction material 68 has a top surface 62 and a bottom surface 64 opposite the top surface 62. A vertical surface 66 may be connected to or perpendicular to the top surface 62 and the bottom surface 64. In one embodiment, the construction material 68 may be formed or created using the form 10 shown in FIG. 1A. The construction material 68 may be formed within the cavity 30 of the form 10. In this case, the top surface 62 may correspond to the first surface adjacent the top panel 14, and the bottom surface 64 may correspond to the second surface adjacent the bottom panel 16, as shown in FIG. 1A. The top surface 62 may include a non-preferential surface closest to the plurality of inlets 18 through which a feed-on solution is provided to the construction material. The depth of the vertical wall 12 in FIG. 1A may correspond to the depth or thickness of the construction material 68.

[0089] As shown in FIG. 1B, the vertical surface 66 extends in a first direction (e.g., the Z direction), the top surface 62 extends in a second direction perpendicular to the first direction, and the bottom surface 64 extends in a second direction (e.g., the X direction).

[0090] 1C illustrates an embodiment of a cross-sectional view of construction material 68 shown in FIG. 1B in which a horizontal slice 67 is cut through construction material 68 and extends in a second direction (e.g., the X direction). Horizontal slice 67 may have a material thickness (e.g., between 0.1 mm and 10 cm, e.g., between 0.1 mm and 1 mm, between 1 mm and 2 mm, between 1 mm and 5 mm, between 1 mm and 1 cm, e.g., between 1 cm and 2 cm, between 1 cm and 5 cm, or between 1 cm and 10 cm, e.g., about 0.1 mm, 0.5 mm, 1 mm, 1.5 mm, 2 mm, 5 mm, 1 cm, 2 cm, or 10 cm thick) and thus may comprise a planar section extending in the second direction.

[0091] FIG. 1D illustrates an embodiment of a side view of the construction material 68 shown in FIG. 1B. As shown in FIG. 1D, the first planar section 54 of the construction material 68 adjacent the top surface 62 has a first thickness 72, and the second planar section 55 of the construction material 68 adjacent the bottom surface 64 has a second thickness 76. The first thickness 72 may be substantially the same as the second thickness 76. In one example, the first thickness 72 may comprise 1.2 cm, and the second thickness 76 may comprise 1.1 cm. A third thickness 74 of an intermediate planar section of the construction material 68 disposed between the first and second planar sections may be determined based on the height of the construction material 68 minus the first thickness 72 and the second thickness 74. The height of the construction material 68 may correspond to the height of the vertical surface 66. The vertical surface 66 of the construction material 68 may include a vertical wall connecting the top surface 62 to the bottom surface 64.

[0092] 1B-1D, the top surface 62 may be parallel to the bottom surface 64. The top surface 62 may be substantially opposite the bottom surface 64. The vertical surface 66 may comprise one of several vertical walls (or walls) between the top surface 62 and the bottom surface 64. The vertical surface 66 may structurally connect (or may connect) the top surface 62 and the bottom surface 64. The body of material of the construction material 68 may encompass or enclose the top surface 62, the vertical surface 66, and the bottom surface 64. The top surface 62, the vertical surface 66, and the bottom surface 64 may comprise the exterior surfaces of the body of material of the construction material 68.

[0093] As shown in FIG. 1D, the construction material 68 includes a portion 52 of the construction material 68, which is enlarged in FIGS. 1E-1F.

[0094] FIG. 1E illustrates an embodiment of aggregate particles in the construction material 68 of FIG. 1D before compaction. FIG. 1F illustrates an embodiment of aggregate particles in the construction material 68 of FIG. 1D after compaction of the aggregate particles. The aggregate particles include aggregate particles 98, which may include sand or gravel particles. As shown in FIGS. 1E-1F, the size of the pore space between the aggregate particles has been reduced by compaction of the aggregate particles. Porosity may refer to the pore space volume within a planar section of the construction material 68 divided by the total volume of the planar section. The path of fluid flow 92 is less restrictive than the path of fluid flow 94 due to the compaction that occurs in the construction material.

[0095] As shown in Figure IF, biological organisms 99 created an environment in which calcium carbonate 97 formed to structurally connect some of the aggregate particles, including aggregate particle 98.

[0096] Compaction of the construction material reduces porosity, along with the spacing between aggregate particles. In concrete, increased aggregate density correlates with improved compressive strength; however, increased aggregate density also reduces pore space. One technical challenge with biocement products and construction materials containing biocement is that smaller pore sizes result in less space to hold bacteria and less space to hold feed material for the bacteria. Furthermore, narrower pore throats caused by smaller pore sizes can result in reduced flow of feed material through the construction material. The combination of less space to hold bacteria, less space to hold feed material for the bacteria, and reduced flow of feed material can result in less cross-linked calcium carbonate in the construction material and reduced compressive strength.

[0097] FIG. 1G illustrates one embodiment of experimental results 82 showing the average compressive strength (in psi) for construction materials over a range of wet green densities (in g / cc) for the construction materials prior to the formation of crosslinked calcium carbonate and / or other binders in the construction materials. As shown in FIG. 1G, the average compressive strength of the construction material in its finished product state varies with the wet green density of the construction material prior to the application of the biocementation process. As shown, a wet green density of 2.10 g / cc provides an average compressive strength of 180 psi, a wet green density of 1.80 provides an average compressive strength of 590 psi, and a wet green density of 1.95 provides the highest average compressive strength of 850 psi. The highest average compressive strength of the construction material occurs when the wet green density is 1.95 g / cc. The wet green density of the construction material prior to the application of the biocementation process may have a significant impact on the resulting average compressive strength of the construction material. The construction materials tested in this experiment were fed with multiple static feed solutions to eliminate confounding variables associated with flow-through feeding.

[0098] 1H shows one embodiment of a graph showing the percentage of total pore volume versus pore diameter for a construction material. As shown, most pores in the construction material have diameters between 170 μm and 300 μm, with pore diameters near 200 μm being the most common pore diameter size.

[0099] FIG. 1I shows one embodiment of experimental results 83 showing the average change in electrical conductivity (or delta EC) for a construction material over a range of average green dry densities (in g / cc) for the construction material. The average change in conductivity is one metric for measuring how quickly the biocementation process proceeds. The amount of cementing reagent consumed in a feed cycle varies depending on the green density of the construction material. As shown, the maximum average delta EC occurs at an average green dry density near 1.75 g / cc. The construction materials tested in this experiment were fed with multiple static feed solutions to eliminate confounding variables associated with flow-through feeding.

[0100] 1J shows one embodiment of a graph illustrating total slice porosity at horizontal slice locations from the non-preferred surface of the construction material. Referring to FIG. 1C, horizontal slice 67 includes a horizontal slice through construction material 68. As shown, a horizontal slice through the construction material at 1.7 mm to 1.8 mm from the non-preferred surface of the construction material has a total slice porosity of approximately 6%.

[0101] FIG. 1K illustrates one embodiment of experimental results 80 showing total open pore porosity versus slice number through a construction material. FIG. 1L illustrates one embodiment of a construction material body 69 including aggregate particles, including aggregate particles 98, bonded together using calcium carbonate, including calcium carbonate 97. As shown, a first horizontal slice 84 (slice number 1) includes the top slice through the construction material body 69, a second horizontal slice 85 (slice number 953) includes an interior slice through the construction material body 69, and a third horizontal slice 86 (slice number 1961) includes the bottom slice through the construction material body 69. The total open pore porosity for the second horizontal slice 85 (slice number 953) is close to 1%. The total open pore porosity for the first horizontal slice 84 (slice number 1) and the third horizontal slice 86 (slice number 1961) is greater than 2%.

[0102] 1M shows one embodiment of experimental results showing compressive strength versus wet green density and compressive strength versus dry green density for construction materials. The construction materials tested in this experiment were fed with a manual flow-through feeding system.

[0103] 1N shows one embodiment of experimental results showing the percentage of calcium carbonate formed (measured by TGA) versus wet green density and the percentage of calcium carbonate versus dry green density for the construction materials. The construction materials tested in this experiment were fed with a manual flow-through feeding system.

[0104] Figures 2A-2B show SEM images taken at the top surface layer of the final product (brick). Areas in the images corresponding to granite and calcium carbonate are shown. Figure 2A shows the area of ​​the block shown enlarged in Figure 2B. Figures 3A-3B show SEM images taken at the top intermediate layer of the final product (brick) (approximately 3-5 mm below the top surface layer shown in Figures 2A-2B). Areas in the images corresponding to granite and calcium carbonate are shown. Figure 3A shows the area within the block shown enlarged in Figure 3B. Figures 4A-4B show SEM images taken at the bottom intermediate layer of the final product (brick) (approximately 8-10 mm below the top intermediate surface layer shown in Figures 3A-3B). Areas in the images corresponding to granite and calcium carbonate are shown. Figure 4A shows the area within the block shown enlarged in Figure 4B. SEM / EDX analysis on different layers from bricks obtained from different batches (and therefore different feed-on solution batch conditions) can be performed and compared.

[0105] FIG. 5A illustrates one embodiment of a system for producing construction materials using one or more biocementation processes. The system includes a chamber 578 for processing the construction materials. As shown, the construction materials include brick 592 and brick 593. While two bricks are shown, other construction materials, such as tiles and blocks, may be used. The system also includes an overhead feed regulator 588 for applying a cementing solution 573 to the construction materials within the processing chamber 578. The overhead feed regulator 588 may regulate the temperature of the cementing solution applied to the construction materials within the processing chamber 578 and may regulate the rate at which the cementing solution is applied to the construction materials. The overhead feed regulator 588 may include heating and / or cooling elements to regulate the temperature of the cementing solution applied to the construction materials. The system also includes a temperature and humidity controller 590 connected to a heat conductor 584 (e.g., a metal grid or metal strip) in thermal communication with the bricks 592-593 within the chamber 578. Thermal conductor 584 may be directly connected to or in physical contact with bricks 592-593. Pallet 586 provides structural support for the construction material within chamber 578. Thermal conductor 584 is disposed between pallet 586 and chamber 578.

[0106] In some embodiments, the temperature and humidity controller 590 may regulate the temperature of the construction material within the chamber 578 via heating or cooling the heat conductor 584. The temperature and humidity controller 590 may use a temperature regulated airflow to regulate or adjust the temperature of the construction material within the chamber 578. The chamber 578 may completely enclose the construction material or may provide an open or ventilated environment.

[0107] In some embodiments, the temperature and humidity controller 590 may include a computing system. The computing system may include a network interface, a processor, a memory, and a disk, all in communication with each other. The network interface, the processor, the memory, and the disk may include actual or virtualized components. In one embodiment, the network interface, the processor, the memory, and the disk are provided by a virtualization infrastructure or a cloud-based infrastructure. The network interface may enable the computing system to connect to one or more networks. By way of example, the network interface may include a wireless network interface and / or a wired network interface. The processor may cause 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). The disk may include a hard disk drive and / or a solid-state drive. In some cases, both the memory and the disk may include hardware storage devices.

[0108] 5A, the system for producing construction materials using one or more biocementation processes also includes a feed storage tank 572 for collecting a residual portion of the cementing solution 573. The residual or unused portion of the cementing solution 573 that passed through or was not utilized by the construction material during the biocementation process may be collected and reused during a subsequent biocementation process. The filtered and / or recycled cementing solution 573 may be transferred to an overhead feed regulator 588 via a pump 582. In some cases, particulate matter in the cementing solution 573 collected by the feed storage tank 572 may be allowed to settle into the collection tank, such that drawing fluid out of the bottom of the collection tank may result in filtering of the recycled cementing solution 573. In one embodiment, the inlet pipe for providing recycled cementing solution 573 to pump 582 may be located at least 10 inches from the bottom of feed storage tank 572 (e.g., distance 571 between the bottom of feed storage tank 572 and the inlet pipe may be 12 inches). The inlet pipe may include additional filtration to remove particulates from recycled cementing solution 573.

[0109] In one embodiment, the temperature of the cementing solution 573 applied to the top of the bricks 592-593 may be less than the temperature applied to the bottom of the bricks 592-593 to reduce the rate of biocement formation for the portions of the bricks 592-593 closer to the top of the bricks 592-593 to which the cementing solution 573 is applied. In one example, the temperature of the cementing solution 573 applied to the top of the bricks 592-593 via the thermal conductor 584 and the temperature applied to the bottom of the bricks 592-593 may be set such that the top 1 cm of the bricks 592-593 has a biocement formation rate that is at least 20% to 50% slower than the biocement formation rate in the bottom 1 cm of the bricks 592-593 closest to the thermal conductor 584.

[0110] 5B shows a flowchart describing one embodiment of a process for producing a construction material. In one embodiment, the process of FIG. 5B is performed using the formwork shown in FIG. 1A. In some embodiments, the process of FIG. 5B is performed using the system for manufacturing a construction material shown in FIG. 5A.

[0111] In step 502, a plurality of aggregate particles is obtained. The plurality of aggregate particles may be provided from a mixture of aggregate materials. The aggregate materials may include sand, gravel, and / or granular materials. In step 504, the plurality of aggregate particles is formed or shaped. In one embodiment, the plurality of aggregate particles is formed using a press to compact or form the plurality of aggregate particles into the desired shape of the finished biocement product.

[0112] In step 506, a cementing solution including a cementing reagent is provided. The cementing reagent may be used to promote calcite precipitation to form bonds between aggregate particles within the plurality of aggregate particles. The cementing solution may be stored in overhead feed regulator 588 of FIG. 5A. In step 508, the cementing solution is set to a first temperature. The cementing solution may be set and maintained at the first temperature using a heating plate or heat exchange system within overhead feed regulator 588. In step 510, the plurality of aggregate particles is set to a second temperature. In one embodiment, the first temperature is less than the second temperature. In another embodiment, the first temperature is greater than the second temperature. The plurality of aggregate particles may be set to the second temperature via direct physical contact with a heating element or heat conductor, such as heat conductor 584 in FIG. 5A.

[0113] In step 512, the cementing solution is filtered. In some cases, the filter may be located in the overhead feed regulator of FIG. 5A. The filter may include a particulate filter or a biofilter. In other cases, particulate matter in the collected cementing solution may settle to the bottom of the feed storage tank 572, so that the feed storage tank 572 may provide filtration, and an inlet line for recycling the cementing solution from the feed storage tank 572 may be positioned to capture the filtered liquid at a threshold distance away from the bottom of the feed storage tank 572.

[0114] In step 514, the cementing solution is applied to or deposited on the plurality of aggregate particles. The cementing solution may be applied to or deposited on the plurality of aggregate particles while the cementing solution is at a first temperature and the plurality of aggregate particles are at a second temperature. In some cases, the temperature of the cementing solution is set so that the liquid for delivering the cementing reagent is below the temperature of the plurality of aggregate particles or below the temperature of a bottom planar section of the plurality of aggregate particles. In some cases, the temperature of the cementing solution is set to be below the temperature of the plurality of aggregate particles by at least a threshold amount (e.g., the temperature of the cementing solution is at least 20 degrees lower than the temperature of the plurality of aggregate particles). In some cases, the bottom surface of the construction material including the plurality of aggregate particles is set to a second temperature higher than the first temperature of the cementing reagent added to the plurality of aggregate particles.

[0115] In step 516, the plurality of aggregate particles are set to a third temperature. The plurality of aggregate particles may be set to a third temperature higher than the second temperature after the cementing solution has been applied to the plurality of aggregate particles. In step 518, cross-linked calcium carbonate crystals are formed between at least two particles of the plurality of aggregate particles. The cross-linked calcium carbonate crystals may be formed while the temperature of the cementing solution is less than the temperature of the plurality of aggregate particles. The cross-linked calcium carbonate crystals may be formed after the cementing solution has been applied to the plurality of aggregate particles.

[0116] Figure 5C shows a flowchart describing an alternative embodiment of a process for producing construction materials. In one embodiment, the process of Figure 5C is performed using the formwork shown in Figure 1A. In some embodiments, the process of Figure 5C is performed using the system for manufacturing construction materials shown in Figure 5A.

[0117] In step 532, a plurality of aggregate particles are provided. In step 534, the plurality of aggregate particles are compressed and / or formed. In step 536, a cementing solution including a cementing reagent is provided. The cementing solution may be stored in a heated vessel with an overhead feed regulator, such as overhead feed regulator 588 of FIG. 5A. In step 538, the cementing solution is regulated to a first temperature. The cementing solution may be regulated using a temperature control circuit in temperature and humidity controller 590 of FIG. 5A, which communicates with a heat exchanger or heat plate in the overhead feed regulator. In step 540, the plurality of aggregate particles are regulated to a second temperature. In one example, the plurality of aggregate particles may correspond to brick 592 of FIG. 5A, and a bottom of brick 592, in thermal communication with heat conductor 584, may be set or regulated to the second temperature via the temperature of heat conductor 584. In step 542, the cementing solution is filtered. In step 544, the cementing solution is applied to the plurality of aggregate particles. In some cases, the filtered cementing solution may be applied to the plurality of aggregate particles using a drip or spray system. In step 546, a biocementation process is performed. The biocementation process may cause a set of cross-linked calcium carbonate crystals to form between at least two of the plurality of aggregate particles.

[0118]

[0023] Figure 5D shows a flowchart describing an alternative embodiment of a process for producing construction materials. In one embodiment, the process of Figure 5D is performed using the formwork shown in Figure 1A. In some embodiments, the process of Figure 5D is performed using the system for manufacturing construction materials shown in Figure 5A.

[0119] In step 552, a plurality of aggregate particles is provided or obtained. In step 554, the plurality of aggregate particles is formed and / or compressed. In step 556, a first filtered cementing solution is provided. The first filtered cementing solution includes a cementing reagent. In step 558, the first filtered cementing solution is heated to a first temperature. In step 560, the first filtered cementing solution is applied to the plurality of aggregate particles. The first filtered cementing solution may be attached to the plurality of aggregate particles while the first filtered cementing solution is adjusted to the first temperature. In step 562, a first biocementation process is performed. The first biocementation process forms a first set of crosslinked calcium carbonate crystals between at least two particles of the plurality of aggregate particles. In step 564, at least a portion of the first filtered cementing solution is collected (e.g., in feed storage tank 572 of FIG. 5A). In step 566, the first filtered cementitious solution is filtered to produce a second filtered cementitious solution. In step 568, the second filtered cementitious solution is attached to a plurality of aggregate particles. In step 570, a second biocementation process is performed. The second biocementation process forms a second set of crosslinked calcium carbonate crystals in a construction material including a plurality of aggregate particles.

[0120] At least one embodiment of the disclosed technology includes a construction material comprising: (a) a plurality of aggregate particles; (b) crosslinked calcium carbonate crystals between at least two members of the plurality of aggregate particles; (c) non-crosslinked calcium carbonate crystals; and (d) at least one biological organism or enzyme that produces at least a portion of the crosslinked calcium carbonate crystals, wherein the construction material comprises at least one surface and a body encapsulated by the at least one surface, and wherein (i) a first average concentration of non-crosslinked calcium carbonate crystals at or near the at least one surface is less than or equal to a second average concentration of crosslinked calcium carbonate crystals at or near the at least one surface, or (ii) the second average concentration differs by no more than 70% from a third average concentration of crosslinked calcium carbonate crystals at or near a cross-section of the body.

[0121] In some cases, the first average concentration is less than or equal to the second average concentration.

[0122] In some cases, the first average concentration is no more than 99%, 95%, 90%, 85%, 80%, 75%, 70%, 65%, or 60% of the second average concentration.

[0123] In some cases, the second average concentration differs from the third average concentration by no more than 50%.

[0124] In some cases, the second average concentration differs from the third average concentration by no more than 69%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0125] In some cases, the second average concentration differs from the third average concentration by no more than 50%. The second average concentration differs from the third average concentration by no more than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0126] In some cases, the first average concentration differs from a fourth average concentration of non-crosslinked calcium carbonate crystals at or near the cross section of the body by no more than 70%.

[0127] In some cases, the first average concentration differs from the fourth average concentration by no more than 69%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0128] In some cases, the at least one biological organism or enzyme comprises urease or cells of a urease-producing microorganism.

[0129] In some cases, the at least one biological organism or enzyme comprises an acid-producing enzyme or cells of an acid-producing microorganism.

[0130] In some cases, the at least one biological organism or enzyme comprises carbonic anhydrase or cells of a carbonic anhydrase-producing microorganism.

[0131] In some cases, the at least one biological organism or enzyme comprises a ureogenic microorganism.

[0132] In some cases, the construction material has an average compressive strength of at least about 1,500 pounds per square inch (psi).

[0133] In some cases, the average compressive strength is at least about 1,500, 1,600, 1,700, 1,800, 1,900, 2,000, 2,200, 2,400, 2,600, 2,800, 2,900, 3,000, 3,200, 3,400, 3,600, 3,800, 4,000, 4,200, 4,400, 4,600, 4,800, 5,000, 5,200, 5,400, 5,600, 5,800, 6,000, 6,200, 6,400, 6,600, or 6,800 psi.

[0134] In some cases, the at least one surface includes a first surface and a second surface, and the first average concentration at or near the first surface differs from the first average concentration at or near the second surface by no more than 50%.

[0135] In some cases, the first average concentration at or near the first surface differs from the first average concentration at or near the second surface by no more than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0136] At least one embodiment of the disclosed technology includes a construction material comprising: (a) a first surface; (b) a second surface substantially opposite the first surface; (c) one or more walls between and connecting the first and second surfaces; and (d) a body encapsulated by the first surface, the second surface, and the one or more walls; (e) a plurality of aggregate particles; (f) crosslinked calcium carbonate crystals between at least two members of the plurality of aggregate particles; (g) non-crosslinked calcium carbonate crystals; and (h) at least one biological organism or enzyme that produces at least a portion of the crosslinked calcium carbonate crystals, wherein a first average concentration of the non-crosslinked calcium carbonate crystals at the first surface is at least about 10% higher than a second average concentration of the non-crosslinked calcium carbonate crystals at the second surface.

[0137] In some cases, the first average concentration is at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, or at least about 100% higher than the second average concentration.

[0138] In some cases, the first average concentration is at least about 10% greater than the third average concentration of non-crosslinked calcium carbonate crystals at or near the cross-section of the body.

[0139] In some cases, the first average concentration is at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, or at least about 100% higher than the third average concentration.

[0140] In some cases, (i) the first average concentration is greater than a fourth average concentration of crosslinked calcium carbonate crystals at or near the first surface, and / or (ii) the fourth average concentration differs by no more than 70% from a fifth average concentration of crosslinked calcium carbonate crystals at or near the cross section of the body.

[0141] In some cases, the fourth average concentration differs from the fifth average concentration by no more than 69%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0142] In some cases, the at least one biological organism or enzyme comprises urease or cells of a urease-producing microorganism.

[0143] In some cases, the at least one biological organism or enzyme comprises an acid-producing enzyme or cells of an acid-producing microorganism.

[0144] In some cases, the at least one biological organism or enzyme comprises carbonic anhydrase or cells of a carbonic anhydrase-producing microorganism.

[0145] In some cases, the at least one biological organism or enzyme comprises a ureogenic microorganism.

[0146] In some cases, the construction material has an average compressive strength of at least about 1,500 pounds per square inch (psi).

[0147] In some cases, the average compressive strength is at least about 1,500, 1,600, 1,700, 1,800, 1,900, 2,000, 2,200, 2,400, 2,600, 2,800, 2,900, 3,000, 3,200, 3,400, 3,600, 3,800, 4,000, 4,200, 4,400, 4,600, 4,800, 5,000, 5,200, 5,400, 5,600, 5,800, 6,000, 6,200, 6,400, 6,600, or 6,800 psi.

[0148] At least one embodiment of the disclosed technology includes a construction material comprising: (a) a first surface; (b) a second surface substantially opposite the first surface; (c) one or more walls between and connecting the first and second surfaces; (d) a body encapsulated by the first surface, the second surface, and the one or more walls, the body comprising a plurality of aggregate particles; (e) calcium carbonate; and (f) at least one biological organism or enzyme that produces at least a portion of the calcium carbonate formed between at least two members of the plurality of aggregate particles, wherein a first average weight percentage of calcium carbonate on the first surface differs by no more than 50% from a second average weight percentage of calcium carbonate on the second surface.

[0149] In some cases, the first average weight percentage differs from the third average weight percentage of calcium carbonate in the cross-section of the body by no more than 50%.

[0150] In some cases, the first average weight percentage differs from the second average weight percentage by no more than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0151] In some cases, the first average weight percentage differs from the third average weight percentage by no more than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0152] At least one embodiment of the disclosed technology includes a construction material comprising: (a) a first surface; (b) a second surface substantially opposite the first surface; (c) one or more walls between and connecting the first and second surfaces; and (d) a body encapsulated by the first surface, the second surface, and the one or more walls, the body comprising a plurality of aggregate particles; (e) calcium carbonate; and (f) at least one biological organism or enzyme that produces at least a portion of the calcium carbonate formed between at least two members of the plurality of aggregate particles, wherein the first average porosity of the construction material is between 15% and 50%.

[0153] In some cases, the first average porosity of the first surface differs from the second average porosity of the second surface by no more than 50%.

[0154] In some cases, the first average porosity differs from the second average porosity by no more than 49%, 45%, 40%, 35%, 30%, 25%, 15%, or 10%.

[0155] In some cases, the first average porosity of the first surface differs from the third average porosity over the cross section of the body by no more than 50%.

[0156] In some cases, the first average porosity differs from the third average porosity by no more than 49%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10%.

[0157] In some cases, the first average porosity of the first surface is between 15% and 50%.

[0158] In some cases, the second average porosity of the second surface is between 15% and 50%.

[0159] In some cases, the third average porosity over the cross section of the body is between 15% and 50%.

[0160] In some cases, the cross section is at least 3 mm from the first surface and the second surface.

[0161] In some cases, the first average porosity of the first surface is greater than the third average porosity over the cross section of the body.

[0162] In some cases, the second average porosity of the second surface is greater than the third average porosity.

[0163] At least one embodiment of the disclosed technology provides a method for producing a calcium carbonate composite comprising: (a) a first surface; (b) a second surface substantially opposite the first surface; (c) one or more walls between and connecting the first and second surfaces; (d) a body encapsulated by the first surface, the second surface, and the one or more walls, the body comprising a plurality of aggregate particles; (e) calcium carbonate; and (f) at least one biological substance or enzyme that produces at least a portion of the calcium carbonate formed between at least two members of the plurality of aggregate particles. The construction materials include: 1) the average green density of the construction material is from about 1.5 grams per cubic centimeter (g / cc) to about 2.5 g / cc; or 2) the average final density of the construction material is from about 1.8 g / cc to about 2.7 g / cc; or 3) the average percentage of voids in the green density is from about 25% to about 46%; or 4) the average percentage of filled voids in the finished product (or average percentage of CaC0 produced) is from about 5% to about 25%; or 5) any combination thereof.

[0164] In some cases, the average green density is from about 1.5 g / cc to about 1.8 g / cc, from about 1.6 g / cc to about 1.9 g / cc, from about 1.7 g / cc to about 2.0 g / cc, from about 1.8 g / cc to about 2.1 g / cc, from about 1.9 g / cc to about 2.2 g / cc, from about 2.0 g / cc to about 2.3 g / cc, or from about 2.1 g / cc to about 2.4 g / cc.

[0165] In some cases, the average green density is from about 1.7 g / cc to about 2.0 g / cc.

[0166] In some cases, the average green density is about 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, or 2.4 g / cc.

[0167] In some cases, the average final density is from about 1.8 g / cc to about 1.9 g / cc, from about 1.9 g / cc to about 2.0 g / cc, from about 2.0 g / cc to about 2.1 g / cc, from about 2.1 g / cc to about 2.2 g / cc, from about 2.2 g / cc to about 2.3 g / cc, from about 2.3 g / cc to about 2.4 g / cc, from about 2.4 g / cc to about 2.5 g / cc, from about 2.5 g / cc to about 2.6 g / cc, or from about 2.6 g / cc to about 2.7 g / cc, and the final density is higher than the green density.

[0168] In some cases, the average final density is from about 2.0 g / cc to about 2.1 g / cc.

[0169] In some cases, the average final density is about 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6 or 2.7 g / cc.

[0170] In some cases, the average percentage of voids in the green density is between about 25% and about 28%, between about 28% and about 31%, between about 31% and about 34%, between about 34% and about 37%, between about 37% and about 40%, between about 40% and about 43%, or between about 43% and about 46%.

[0171] In some cases, the average percentage of voids in the green density is between about 30% and about 42%.

[0172] In some cases, the average percentage of voids in the green density is about 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 31%, 42%, 43%, 44%, 45%, 46%, or 47%.

[0173] In some cases, the average percentage of CaCO3 produced is about 5% to about 10%, about 10% to about 15%, about 15% to about 20%, or about 20% to about 25%.

[0174] In some cases, the percentage of CaCO3 produced averages between 10% and about 23%.

[0175] In some cases, the average percentage of CaC0 produced is about 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, or 25%.

[0176] At least one embodiment of the disclosed technology includes: (a) a system for producing a construction material, the system including: (i) a base; (ii) one or more walls that, together with the base, define a space; (iii) an inlet configured to add a cementing reagent to the space; and (iv) an outlet configured to remove a mobile phase containing depleted cementing reagent from the space; (b) a heat exchange system in thermal communication with the plurality of frameworks; and (c) a controller in communication with the inlet, the outlet, and the heat exchange system, the controller configured to control a duty cycle of the system, the duty cycle including adding the cementing reagent to the space, removing the mobile phase from the space, and maintaining a temperature of the base higher than a temperature of the cementing reagent at the inlet while adding the cementing reagent.

[0177] In some cases, the duty cycle further includes cooling / heating the bottom and / or one or more walls after the addition of the cementing reagent is completed.

[0178] In some cases, the duty cycle further includes cooling / heating the inlet during and / or after addition of the cementing reagent.

[0179] In some cases, the duty cycle further includes adding air, oxygen, or ozone to the space or the top of the space; and / or removing air, oxygen, or ozone from the space or the top of the space.

[0180] In some cases, the duty cycle further includes radiating into space using ultraviolet light.

[0181] In some cases, the duty cycle further includes vibrating a plurality of frameworks.

[0182] At least one embodiment of the disclosed technology includes a method of producing a construction material, comprising: (a) adding a plurality of aggregate particles and at least one biological organism or enzyme to a framework, thereby forming a framed plurality of aggregate particles including at least one surface and a body encapsulated by the at least one surface, wherein the at least one biological organism or enzyme is within at least the body; (b) supplying a cementing reagent to the framed plurality of aggregate particles; (c) controlling a first temperature of the body relative to (i) a second temperature of the supplied cementing reagent and / or (ii) a third temperature of a solution phase above the framed plurality of aggregate particles; and (d) forming crosslinked calcium carbonate crystals between at least two members of the framed plurality of aggregate particles, and non-crosslinked calcium carbonate crystals from a starting material produced by the at least one biological organism or enzyme.

[0183] In some cases, the control in (c) includes heating / cooling the bottom of the framework.

[0184] In some cases, the control in (c) includes heating the bottom of the framework.

[0185] In some cases, the control in (c) includes heating / cooling of the supplied cementing reagent.

[0186] In some cases, the control in (c) includes cooling the supplied cementing reagent.

[0187] In some cases, the control in (c) involves heating / cooling a solution phase above a plurality of framed aggregate particles.

[0188] In some cases, the controlling in (c) includes cooling the solution phase above the framed plurality of aggregate particles.

[0189] In some cases, the method further comprises adding air, oxygen, or ozone to the top of the framework; and / or removing air, oxygen, or ozone from the top of the framework.

[0190] In some cases, the method further includes irradiating the framework with ultraviolet light.

[0191] In some cases, the method further includes vibrating the plurality of frameworks.

[0192] In some cases, the method further comprises removing the mobile phase from the framework, the mobile phase comprising the depleted cementing reagent.

[0193] In some cases, the method further includes controlling a growth time for at least one biological organism or enzyme within the body prior to providing a dose of calcium ions to the plurality of framed aggregate particles.

[0194] In some cases, the method further includes controlling the concentration and / or rate of delivery of a dose of calcium to the framed plurality of aggregate particles.

[0195] At least one embodiment of the disclosed technology comprises: calcium carbonate and Cl - , OCN - and CN - and at least a trace amount of a salt comprising an anion selected from the group consisting of:

[0196] At least one embodiment of the disclosed technology includes a construction material comprising a plurality of aggregate particles bound together by one or more cohesive bridges comprising calcium carbonate and at least one nitrogen-containing compound; wherein the ratio of nitrogen to calcium in the cohesive bridges is at least 0.15 (e.g., at least 0.2, 0.3, 0.4, 0.5, or 0.6) as measured by X-ray photoelectron spectroscopy at the surface of the construction material or at a cross-section of a portion thereof.

[0197] At least one embodiment of the disclosed technology includes a cementitious material comprising: (a) calcium; (b) carbonate; and (c) at least 20 ppb of chlorine, cyanide, cyanate, fulminate, and / or a combination of one or more thereof.

[0198] At least one embodiment of the disclosed technology includes a cementitious material comprising: (a) calcium; (b) carbonate; and (c) between 10 ppb and 1000 ppb of chlorine, cyanide, cyanate, fulminate, and / or one or more combinations thereof. In some cases, the cementitious material includes between 50 ppb and 150 ppb of chlorine, between 150 ppb and 500 ppb of chlorine, or between 500 ppb and 1000 ppb of chlorine. In some cases, the cementitious material contains between 10 ppb and 20 ppb cyanide, between 10 ppb and 50 ppb cyanide, or between 50 ppb and 100 ppb cyanide, between 50 ppb and 150 ppb cyanide, between 100 ppb and 200 ppb cyanide, between 100 ppb and 500 ppb cyanide, between 200 ppb and 1000 ppb cyanide, or between 500 ppb and 1000 ppb cyanide. In some cases, the cementitious material contains between 10 ppb and 20 ppb cyanide, between 10 ppb and 50 ppb cyanide, or between 50 ppb and 100 ppb cyanide, between 50 ppb and 150 ppb cyanide, between 100 ppb and 200 ppb cyanide, between 100 ppb and 500 ppb cyanide, between 200 ppb and 1000 ppb cyanide, or between 500 ppb and 1000 ppb cyanide. In some cases, the cementitious material contains between 10 ppb and 20 ppb of fulminate, between 10 ppb and 50 ppb of fulminate, or between 50 ppb and 100 ppb of fulminate, between 50 ppb and 150 ppb of fulminate, between 100 ppb and 200 ppb of fulminate, between 100 ppb and 500 ppb of fulminate, between 200 ppb and 1000 ppb of fulminate, or between 500 ppb and 1000 ppb of fulminate.

[0199] At least one embodiment of the disclosed technology includes a construction material comprising a plurality of aggregate particles bound together by one or more cohesive bridges, the cohesive bridges comprising calcite crystals having an average particle size of about 100 μm or less at a density of at least 10,000 crystals per square centimeter as measured on the surface of the construction material by TEM / SEM.

[0200] At least one embodiment of the disclosed technology includes a construction material comprising a plurality of aggregate particles bound together by one or more cohesive bridges, the cohesive bridges comprising calcite crystals having an average particle size of about 100 μm or less at a density of between 5K crystals per square centimeter and 500K crystals per square centimeter as measured on the surface of the construction material by TEM / SEM.

[0201] At least one embodiment of the disclosed technology includes a construction material comprising: a plurality of aggregate particles bonded together by one or more cohesive bridges comprising calcium; and a plurality of pores substantially free of solid material; wherein the construction material comprises about 20-50 volume percent pores, and the plurality of pores have an average pore diameter of about 1-400 μm (e.g., about 4-275 μm).

[0202] At least one embodiment of the disclosed technology comprises a construction material comprising: a first surface; a second surface substantially opposite the first surface; one or more walls between and connecting the first and second surfaces; a plurality of aggregate particles encapsulated by the first surface, the second surface, and the one or more walls; and calcium carbonate, at least a portion of which is formed between at least two of the plurality of aggregate particles by the biological activity of at least one biological organism or enzyme, and a first average weight of the first portion of the calcium carbonate in a first planar section of the construction material differs by 50% or less from a second average weight of the second portion of the calcium carbonate in a second planar section of the construction material.

[0203] The disclosure of this specification includes the subject matter set forth in the following sections: Item 1. A construction material comprising: a first surface; a second surface substantially opposite the first surface; one or more walls between and connecting the first and second surfaces; a plurality of aggregate particles encapsulated by the first surface, the second surface, and the one or more walls; and calcium carbonate, wherein at least a portion of the calcium carbonate is formed between at least two of the plurality of aggregate particles by the biological activity of at least one biological organism or enzyme, and a first average weight of the first portion of the calcium carbonate within a first planar section of the construction material differs by 50% or less from a second average weight of the second portion of the calcium carbonate within a second planar section of the construction material.

[0204] Item 2. The construction material of item 1, wherein the third portion of calcium carbonate indirectly structurally connects at least two particles of the plurality of aggregate particles.

[0205] Item 3. The construction material of item 1, wherein at least a portion of the calcium carbonate provides a structural connection between at least two particles of the plurality of aggregate particles.

[0206] Item 4. The construction material of Item 3, wherein at least a portion of the calcium carbonate comprises cross-linked calcium carbonate.

[0207] Item 5. The construction material of item 1, wherein the first average weight of the first portion of calcium carbonate is less than the second average weight of the second portion of calcium carbonate.

[0208] Item 6. The construction material of Item 1, wherein the first planar section is adjacent to a non-preferred surface of the construction material; and the second planar section is adjacent to a preferred surface of the construction material.

[0209] Item 7. The construction material of Item 1, wherein the first average weight differs by no more than 20% from a third average weight of a third planar section of the construction material disposed between the first planar section and the second planar section.

[0210] Item 8. Construction materials of item 7, where the first average weight is greater than the third average weight.

[0211] Item 17. The construction material of item 1, wherein the first planar section is adjacent to the first surface; and the second planar section is adjacent to the second surface.

[0212] Item 18. A construction material comprising: a first surface; a second surface substantially opposite the first surface; one or more walls between and connecting the first and second surfaces; a body comprising a plurality of aggregate particles, the body being encapsulated by the first surface, the second surface, and the one or more walls; and calcium carbonate, wherein at least a portion of the calcium carbonate is formed between at least two of the plurality of aggregate particles by at least one biological organism or enzyme, and wherein the construction material has an average dry green density of about 1.52 grams per cubic centimeter (g / cc) to about 2.55 g / cc.

[0213] Item 19. The construction material of Item 18, wherein the average percentage of voids in the construction material is about 25% to about 46%.

[0214] Item 20. A construction material comprising: a first surface; a second surface substantially opposite the first surface; one or more walls between and connecting the first and second surfaces; a body comprising a plurality of aggregate particles, the body being encapsulated by the first surface, the second surface, and the one or more walls; and calcium carbonate, wherein at least a portion of the calcium carbonate is formed between at least two of the plurality of aggregate particles by at least one biological organism or enzyme, and the construction material has an average final density of about 1.83 grams per cubic centimeter (g / cc) to about 2.72 g / cc.

[0215] Item 21. The construction material of Item 20, wherein the average percentage of voids in the construction material is about 5% to about 25%.

[0216] Item 25. A method for producing a construction material, comprising: obtaining a plurality of aggregate particles; forming a plurality of aggregate particles; providing a cementing solution containing a cementing reagent; setting the cementing solution to a first temperature; setting the plurality of aggregate particles to a second temperature different from the first temperature; supplying the cementing solution to the plurality of aggregate particles while the cementing solution is at the first temperature and the plurality of aggregate particles is at the second temperature; and forming a set of cross-linked calcium carbonate crystals between at least two particles of the plurality of aggregate particles after applying the cementing solution to the plurality of aggregate particles.

[0217] Item 26. The method of item 25, further comprising filtering the cementing solution before applying the cementing solution to the plurality of aggregate particles.

[0218] Item 27. The method of Item 25, wherein the first temperature is less than the second temperature.

[0219] Item 31. A method for producing a construction material, comprising: providing a plurality of aggregate particles; compressing the plurality of aggregate particles so that the construction material has an average dry compacted density of about 1.52 grams per cubic centimeter (g / cc) to about 2.55 g / cc; providing a cementing solution containing a cementing reagent; applying the cementing solution to the plurality of aggregate particles while the cementing solution is at a first temperature and the plurality of aggregate particles are at a second temperature different from the first temperature; and performing a biocementation process after applying the cementing solution to the plurality of aggregate particles, causing a set of cross-linked calcium carbonate crystals to form between at least two particles of the plurality of aggregate particles.

[0220] Item 32. The method of item 31, further comprising producing a construction material having an average final density of the construction material of about 1.83 g / cc to about 2.72 g / cc.

[0221] Item 33. The method of any one of Items 31 to 32, wherein conducting a biocementation process includes forming a set of cross-linked calcium carbonate crystals through the biological activity of at least one biological organism or enzyme.

[0222] Item 37. A method for producing a construction material, comprising: providing a plurality of aggregate particles; forming a plurality of aggregate particles; providing a first filtered cementing solution including a cementing reagent; applying the first filtered cementing solution to the plurality of aggregate particles; conducting a first biocementation process to form a first set of crosslinked calcium carbonate crystals between at least two of the plurality of aggregate particles; collecting at least a portion of the first filtered cementing solution while applying the first filtered cementing solution to the plurality of aggregate particles; filtering the first filtered cementing solution to produce a second filtered cementing solution; and applying the second filtered cementing solution to the plurality of aggregate particles.

[0223] Item 39. The method of Item 37, wherein filtering the first filtered cementing solution to produce a second filtered cementing solution includes allowing particulate matter in the first filtered cementing solution to settle in a collection tank.

[0224] The flowcharts and block diagrams in the figures provide illustrations of the organization, functionality, and operation of possible implementations of systems, methods, and computer program products according to various aspects of the disclosed technology. In this regard, each step in the flowcharts may correspond to a program module or portion of computer program code, which may include one or more computer-executable instructions to achieve the specified functionality. In some implementations, the functionality described in the steps may occur out of the order shown in the figures. For example, two steps shown in succession may in fact be executed substantially simultaneously, or the steps may sometimes be executed in the reverse order, depending on the functionality involved. In some implementations, steps may be omitted or other steps may be added without departing from the spirit and scope of the inventive subject matter.

[0225] In some implementations, the functionality described in the steps may be implemented using hardware, software, or a combination of hardware and software. For example, hardware may include a microcontroller, a microprocessor, a field programmable gate array (FPGA), and electronic circuitry.

[0226] It should be noted that for purposes of this specification, the dimensions of the various features shown in the figures are not necessarily drawn to scale.

[0227] For purposes of this specification, references herein to "an embodiment," "one embodiment," "some embodiments," "another embodiment," and other variations thereof may be used to describe various features, functions, or structures included in at least one or more embodiments, and do not necessarily refer to the same embodiment unless the context clearly indicates otherwise.

[0228] For purposes of this specification, a connection may be a direct connection or an indirect connection (e.g., through another part). In some cases, when an element is said to be connected or coupled to another element, the element may be directly connected to the other element, or indirectly connected to the other element through intervening elements. When an element is said to be directly connected to another element, there are no intervening elements between the element and the other element.

[0229] For purposes of this specification, the term "based on" may be read as "based at least in part on."

[0230] For purposes of this specification, without additional context, the use of numerical terms such as "first" object, "second" object, and "third" object may not imply an ordering of the objects, but may instead be used to identify or distinguish between separate objects for identification purposes.

[0231] For purposes of this specification, the term "set" of objects may refer to one or more "sets" of objects.

[0232] For purposes of this specification, the phrases "a first object corresponds with a second object" and "a first object corresponds to a second object" may indicate that the first object and the second object are equivalent, similar, or related in characteristics or function.

[0233] For purposes of this specification, the term "or" should be interpreted both conjunctively and disjunctively. A list of items joined by the conjunction "or" should not be read as requiring mutual exclusivity between the items; rather, it should be read as "and / or" unless expressly stated otherwise. As used herein, the terms "at least one," "one or more," and "and / or" are open-ended expressions that are both conjunctive and disjunctive in operation. The phrase "A and / or B" encompasses embodiments having element A only, element B only, or elements A and B together. The phrase "at least one of A, B, and C" encompasses embodiments having element A only, element B only, element C only, elements A and B together, elements A and C together, elements B and C together, or elements A, B, and C together. As used herein, the indefinite articles "a" and "an" should typically be interpreted to mean "at least one" or "one or more," unless expressly stated otherwise.

[0234] For purposes of this specification, whenever the terms "at least," "greater than," or "greater than or equal to" precede the first number in a series of two or more numbers, the terms "at least," "greater than," or "greater than or equal to" apply to each and every one of those numbers in the 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.

[0235] For purposes of this specification, whenever the terms "less than or equal to," "less than," or "less than or equal to" precede the first number in a series of two or more numbers, the terms "less than or equal to," "less than," or "less than or equal to" apply to each of that number in the 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.

[0236] Some embodiments disclosed herein contemplate numerical ranges. When a range is present, it includes the endpoints of the range. Furthermore, all subranges and values ​​within that range exist as if explicitly written out. The terms "about," "approximately," or "substantially" may mean within an acceptable error range for a particular value, which may depend, in part, on how the value is measured or determined, e.g., the limitations of the measurement system. For example, "about" may mean within 1 or more than 1 standard deviation, per the practice in the art. Alternatively, "about" may 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, the term "about" may be assumed to mean within an acceptable error range for the particular value.

[0237] The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above detailed description. Generally, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and claims, but should be construed to include all possible embodiments, along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the present disclosure.

Claims

1. a first surface (62); a second surface (64) substantially opposite the first surface; one or more walls (66) between and connecting the first and second surfaces; a plurality of aggregate particles (98) encapsulated by a first surface, a second surface, and one or more walls; and Calcium carbonate (97) A construction material comprising: at least a portion of the calcium carbonate is formed between at least two of the plurality of aggregate particles by the biological activity of at least one biological organism or enzyme; 1. The construction material, wherein a first average weight of a first portion of calcium carbonate in a first planar section of the construction material differs from a second average weight of a second portion of calcium carbonate in a second planar section of the construction material by no more than 50%.

2. 10. The construction material of claim 1, wherein a third portion of calcium carbonate indirectly structurally connects at least two particles of the plurality of aggregate particles.

3. 3. The construction material of claim 1 or 2, wherein at least a portion of the calcium carbonate provides a structural connection between at least two particles of the plurality of aggregate particles.

4. 4. The construction material of claim 3, wherein at least a portion of the calcium carbonate comprises cross-linked calcium carbonate.

5. 2. The construction material of claim 1, wherein the first average weight of the first portion of the calcium carbonate is less than the second average weight of the second portion of the calcium carbonate.

6. the first planar section is adjacent to a non-preferential surface of the construction material; the second planar section is adjacent to a preferred surface of the construction material; The construction material according to any one of claims 1 to 5.

7. 2. The construction material of claim 1, wherein the first average weight differs by no more than 20% from a third average weight of a third planar section of the construction material disposed between the first planar section and the second planar section.

8. 8. The construction material of claim 7, wherein the first average weight is greater than the third average weight.

9. 8. The construction material of claim 7, wherein the first average weight is less than the third average weight.

10. 10. The construction material of claim 1, wherein the first average weight differs from the second average weight by no more than 20%.

11. 2. The construction material of claim 1, wherein the calcium carbonate comprises crosslinked calcium carbonate crystals and non-crosslinked calcium carbonate crystals, and wherein a first average concentration of non-crosslinked calcium carbonate crystals in the first planar section is less than a second average concentration of crosslinked calcium carbonate crystals in the second planar section.

12. 12. The construction material of claim 11, wherein the second average concentration differs by no more than 70% from a third average concentration of crosslinked calcium carbonate crystals in a third planar section disposed between the first and second planar sections.

13. 13. The construction material of claim 12, wherein the third average concentration is greater than the first average concentration.

14. 12. The construction material of claim 11, wherein the non-crosslinked calcium carbonate comprises precipitates that are not connected to any of the plurality of aggregate particles.

15. 12. The construction material of claim 11, wherein the crosslinked calcium carbonate comprises precipitates connecting at least two of the plurality of aggregate particles.

16. 12. The construction material of claim 11, wherein the at least one biological organism or enzyme comprises urease or cells of a urease-producing microorganism.

17. the first planar section is adjacent to the first surface; the second planar section is adjacent to the second surface; 10. The construction material of claim 1.

18. a first surface (62); a second surface (64) substantially opposite the first surface; one or more walls (66) between and connecting the first and second surfaces; a body (69) comprising a plurality of aggregate particles and enclosed by a first surface, a second surface, and one or more walls; and Calcium carbonate (97) A construction material comprising: at least a portion of the calcium carbonate is formed between at least two of the plurality of aggregate particles by at least one biological microorganism or enzyme; The construction material has an average dry green density of from about 1.52 grams per cubic centimeter (g / cc) to about 2.55 g / cc.

19. 20. The construction material of claim 18, wherein the average porosity in the construction material is from about 25% to about 46%.

20. a first surface (62); a second surface (64) substantially opposite the first surface; one or more walls (66) between and connecting the first and second surfaces; a body (69) comprising a plurality of aggregate particles and enclosed by a first surface, a second surface, and one or more walls; and Calcium carbonate (97) A construction material comprising: at least a portion of the calcium carbonate is formed between at least two of the plurality of aggregate particles by at least one biological organism or enzyme; The construction material has an average final density of from about 1.83 grams per cubic centimeter (g / cc) to about 2.72 g / cc.

21. 21. The construction material of claim 20, wherein the average porosity in the construction material is from about 5% to about 25%.

22. a first surface (62); a second surface (64) substantially opposite the first surface; one or more walls (66) between and connecting the first and second surfaces; a plurality of aggregate particles (98) encapsulated by a first surface, a second surface, and one or more walls; and Calcium carbonate (97) A construction material comprising: at least a portion of the calcium carbonate is formed between at least two of the plurality of aggregate particles by the biological activity of at least one biological organism or enzyme; 1. The construction material, wherein a first average porosity within a first planar section of the construction material is less than a second average porosity within a second planar section of the construction material before at least a portion of the calcium carbonate is formed between at least two of the plurality of aggregate particles.

23. 23. The construction material of claim 22, wherein a first average porosity in the first planar section is less than a second average porosity in the second planar section.

24. a first surface (62); a second surface (64) substantially opposite the first surface; one or more walls (66) between and connecting the first and second surfaces; a body (69) encapsulated by a first surface, a second surface, and one or more walls, the body (69) including a plurality of aggregate particles (98); Calcium carbonate (97), and at least one biological organism (99) or enzyme that generates at least a portion of the calcium carbonate formed between at least two members of said plurality of aggregate particles; A construction material comprising: The construction material, wherein a first average percentage by weight of calcium carbonate on the first surface differs from a second average percentage by weight of calcium carbonate on the second surface by no more than 50%.

25. 1. A method for producing a construction material, comprising: Obtaining a plurality of aggregate particles (502); forming a plurality of aggregate particles (504); providing a cementing solution comprising a cementing reagent (506); setting the cementing solution to a first temperature (508); setting the plurality of aggregate particles to a second temperature different from the first temperature (510); delivering (514) the cementitious solution to the plurality of aggregate particles while the cementitious solution is at the first temperature and the plurality of aggregate particles is at the second temperature; and forming a set of cross-linked calcium carbonate crystals between at least two of the plurality of aggregate particles after applying the cementing solution to the plurality of aggregate particles (518); a method for producing said construction material comprising:

26. 26. The method of claim 25, further comprising filtering the cementing solution before applying the cementing solution to the plurality of aggregate particles.

27. the first temperature is less than the second temperature; setting the plurality of aggregate particles to the second temperature includes heating a form containing the plurality of aggregate particles to the second temperature.

26. The method of claim 25.

28. 26. The method of claim 25, further comprising setting the plurality of aggregate particles to a third temperature different from the second temperature before forming the set of crosslinked calcium carbonate crystals between at least two particles of the plurality of aggregate particles.

29. the third temperature is greater than the second temperature; setting the plurality of aggregate particles to the third temperature includes heating a thermal conductor in physical contact with the plurality of aggregate particles to the third temperature.

29. The method of claim 28.

30. collecting a portion of the cementitious solution during application of the cementitious solution to the plurality of aggregate particles; and reusing a portion of the cementing solution by reapplying the portion of the cementing solution to the plurality of aggregate particles.

26. The method of claim 25, further comprising:

31. 1. A method for producing a construction material, comprising: providing a plurality of aggregate particles (532); compressing (534) the plurality of aggregate particles so that the construction material has an average dry green density of from about 1.52 grams per cubic centimeter (g / cc) to about 2.55 g / cc; providing a cementing solution comprising a cementing reagent (536); applying the cementitious solution to the plurality of aggregate particles while the cementitious solution is at a first temperature and the plurality of aggregate particles is at a second temperature different from the first temperature (544); and performing a biocementation process (546) after applying the cementing solution to the plurality of aggregate particles, whereby a set of cross-linked calcium carbonate crystals forms between at least two of the plurality of aggregate particles; a method for producing said construction material comprising:

32. Producing said construction material having an average final density of said construction material of from about 1.83 g / cc to about 2.72 g / cc.

32. The method of claim 31 further comprising:

33. 33. The method of claim 31 or 32, wherein the average dry green density is from about 1.73 g / cc to about 1.78 g / cc.

34. 33. The method of claim 31 or 32, wherein the average dry green density is from about 1.80 g / cc to about 2.00 g / cc.

35. 33. The method of claim 31 or 32, wherein the average dry green density is from about 2.15 g / cc to about 2.20 g / cc.

36. 36. The method of any one of claims 31 to 35, wherein conducting the biocementation process comprises forming the set of crosslinked calcium carbonate crystals by the biological activity of at least one biological organism or enzyme.

37. providing a plurality of aggregate particles (552); forming a plurality of aggregate particles (554); providing a first filtered cementing solution (556) comprising a cementing reagent; applying the first filtered cementitious solution to the plurality of aggregate particles (560); conducting a first biocementation process (562) to form the first set of crosslinked calcium carbonate crystals between at least two particles of the plurality of aggregate particles; collecting at least a portion of the first filtered cementitious solution while applying the first filtered cementitious solution to the plurality of aggregate particles (564); filtering the first filtered cementing solution to produce a second filtered cementing solution (566); and applying the second filtered cementing solution to the plurality of aggregate particles (568); a method for producing said construction material comprising:

38. 40. The method of claim 37, further comprising conducting (570) a second biocementation process to form a second set of crosslinked calcium carbonate crystals in the construction material comprising the plurality of aggregate particles.

39. 39. The method of claim 37 or 38, wherein filtering the first filtered cementing solution to produce the second filtered cementing solution comprises allowing particulate matter in the first filtered cementing solution to settle in a collection tank.

40. setting the first filtered cementing solution to a first temperature; and 38. The method of claim 37, further comprising setting the plurality of aggregate particles at a second temperature higher than the first temperature, and performing the first biocementation process while the first filtered cementitious solution is at the first temperature and the plurality of aggregate particles is at the second temperature.

Images