Modular cladding slab for marine structures for restoring marine habitats, and method for manufacturing same

Abstract

The present invention relates to a modular cladding slab for marine structures for restoring marine habitats, comprising: a three-dimensional design with structural heterogeneity having a simple, medium or high complexity based on groove or relief features, their quantity, variable width, undulation and direction; in-situ installation or securing means; and bio-enhanced concrete, formed by a mixture of cement for the marine environment and calcium carbonate (CaCO3), as a material for manufacturing by moulding.

Description

[0001] MODULAR SLAB FOR MARINE STRUCTURE CLADDING FOR THE RESTORATION OF MARINE HABITATS; AND MANUFACTURING PROCESS.

[0002] DESCRIPTIVE MEMORANDUM

[0003] SCOPE

[0004] The present invention relates to the construction industry, in particular to construction in marine environments and the restoration of natural habitats.

[0005] BACKGROUND

[0006] Natural marine habitats, such as reefs, estuaries, and mangroves, play a crucial role in maintaining biodiversity and providing essential ecosystem services, including oxygen production, carbon sequestration, and protection against extreme weather events. However, the expansion of underwater and coastal infrastructure, such as ports, breakwaters, and offshore platforms, has caused significant alterations to these environments. These structures, often designed without considering ecological integration, fragment ecosystems, alter hydrodynamic flows, and modify sedimentary conditions, which can lead to a drastic reduction in habitat availability for many marine species.

[0007] Furthermore, coastal urbanization and industrial development have intensified pollution and eutrophication in areas near these structures, exacerbating biodiversity loss and further degrading habitat quality. The loss of coastal and submarine habitats not only affects the species that depend on them for survival but also compromises the ecological resilience of our oceans to environmental and climate change. This cumulative impact jeopardizes natural cycles and the stability of these ecosystems, underscoring the importance of addressing marine habitat health with a holistic and sustainable approach. Habitat heterogeneity and complexity can be understood and manipulated through key concepts such as density, the number of component types, relative abundance, and size variability of these components, which mimic natural heterogeneity.In the context of artificial habitats, "information-based complexity" refers to the variety and quantity of information a system can contain, which is reflected in the diversity and arrangement of its physical components. When designing artificial substrates such as modules or tiles for ecological restoration, the topography and other features can be deliberately varied to increase this complexity. For example, adjusting the density of elements within the substrate or varying the size and shape of these components can result in different levels of structural complexity. These modifications not only affect the physical appearance of the habitat but also how species interact with it, promoting biodiversity by creating multiple microhabitats and ecological niches.These design principles allow the creation of artificial habitats that, although sharing the same surface area, differ significantly in their complexity and ability to support diverse life forms.

[0008] Preliminary art

[0009] US patent 2019212455A1 describes a marine habitat substrate tile made of concrete that is portable for humans and provides a higher calcium carbonate content and interstitial spaces for feeding and habitat development for oysters. Specifically, a reef restoration and oyster farming slab is disclosed, comprising: a concrete slab comprising at least 25% by weight of calcium carbonate; wherein the concrete slab comprises a base and a surface disposed upon the base and comprising a plurality of spaced projections and interstitial spaces; and wherein the plurality of spaced projections and interstitial spaces provide a three-dimensional surface. However, inherent challenges to the technique remain that limit its long-term application and effectiveness.Although the tile promotes a higher calcium carbonate content and interstitial spaces for oyster development, the practicality of these solutions on a large scale and their cumulative environmental impact may be questionable.

[0010] Indeed, the patent mentions the portability of the tiles as an advantage, allowing for installation without heavy machinery. However, this approach may not be sustainable in large-scale projects where the required restoration scale is vast. Individual tiles, while useful in small areas or under controlled conditions, do not provide a viable solution for restoring large reefs or addressing large-scale habitat loss. This limitation underscores the need for a more holistic and less fragmented strategy in marine habitat restoration.

[0011] US patent 2022354095A1 discloses a marine ecological engineering construction method, an asphalt cement-based coating, and a method for preparing the coating. The asphalt cement-based coating can enable discarded concrete to induce the settlement of sessile organisms, thus achieving the goal of using discarded concrete for ecological engineering construction. It also incorporates the characteristics of waste recycling and marine ecological restoration. This solution addresses environmental problems by recycling materials and enhancing marine biodiversity. However, several challenges and limitations arise regarding the effectiveness and long-term applicability of this technology in marine habitat restoration.

[0012] Thus, the idea of ​​recycling discarded concrete for ecological restoration purposes faces limitations in its practical application. The effectiveness of the coating in consistently inducing organism settlement can vary significantly depending on the specific environmental conditions of the installation site. Furthermore, the long-term durability of the coating and its ability to maintain its inductive properties under harsh marine conditions are not clearly demonstrated, which could result in the need for frequent maintenance or reapplication, increasing costs and human intervention. Additionally, the scale of implementation and logistical feasibility of applying this coating to large quantities of discarded concrete in diverse marine environments present a considerable challenge.The logistics of processing and transporting coated concrete to specific sites need to be optimized to ensure that this approach is environmentally and economically sustainable and efficient.

[0013] Technical problem addressed by the invention

[0014] The present invention addresses a technical problem: improving the viability, durability, and scalability of modular slabs for marine habitat restoration, considering a habitat-specific eco-engineering application. Current techniques still present limitations for their implementation in large-scale projects or in the restoration of large reefs.

[0015] Technical Solution of the present invention

[0016] An object of the present invention is a modular slab for cladding marine structures with structural heterogeneity with a complexity determined by grooves or reliefs, its variable width, undulation and direction for the restoration of marine habitats.

[0017] Another object of the present invention is a manufacturing process for modular slabs for cladding marine structures with heterogeneity of shape with a complexity determined by grooves or reliefs, their variable width, undulation and direction for the restoration of marine habitats.

[0018] Advantages of the present invention

[0019] An advantage of the present invention is the ability to create modular slabs with customized structural heterogeneity specifically tailored to the needs of a local marine ecosystem. This is crucial for the success of habitat restoration projects, as it allows for the replication of the natural complexity necessary to support diverse forms of marine life. Unlike more generic solutions in the prior art, these slabs can be designed with a variety of patterns and complexities that encourage more effective and sustainable colonization by keystone species, increasing biodiversity and ecosystem resilience.

[0020] Another advantage of the present invention is that the modular slabs are designed for easy on-site installation, thanks to pre-integrated anchoring means that allow for robust and durable fastening without the need for heavy machinery. This contrasts significantly with conventional techniques that can require complex equipment and logistics for installation, often increasing costs and the project's environmental footprint. The ease and efficiency of installation of these modular slabs significantly reduce operating costs and the environmental impact associated with marine restoration projects.

[0021] Another advantage of the present invention is that the slabs are made of materials that allow for long-term durability and stability under harsh marine conditions. While other solutions may deteriorate or lose effectiveness over time due to corrosion or material wear, the slabs of the present invention are designed to withstand such conditions, ensuring a long-term solution for marine habitat restoration. This not only enhances the project's sustainability but also ensures that the investment in ecological restoration will provide ongoing environmental benefits.

[0022] BRIEF DESCRIPTION OF THE FIGURES

[0023] The following figures describe a preferred and exemplary embodiment of the present invention. It should be appreciated that the figures are provided for illustrative purposes only and that the invention is not limited by these illustrations. Well-known components, materials, or methods are not necessarily described in great detail to avoid obscuring the present description. Any specific structural and functional details described herein should not be construed as limiting, but merely as a basis for the claims and as a representative basis for teaching a person skilled in the art to employ the invention in various ways.

[0024] Figure 1 presents a slab with structural heterogeneity of simple complexity according to the present invention.

[0025] Figure 2 presents a slab with structural heterogeneity of medium complexity according to the present invention.

[0026] Figure 3 presents a slab with high structural heterogeneity according to the present invention.

[0027] Figures 4 to 6 respectively present a different arrangement or pattern from the slab in Figure 2.

[0028] Figures 7 to 9 respectively present a different arrangement or pattern than the slab in Figure 3.

[0029] Figure 10 presents a photograph of thermal tests performed on the slab of Figure 1 and 3 respectively.

[0030] DETAILED DESCRIPTION OF THE INVENTION

[0031] According to the present invention, a modular slab for lining marine structures for the restoration of marine habitats is provided, comprising: a three-dimensional design with structural heterogeneity with simple, medium, or high complexity, based on groove or relief characteristics, their quantity, variable width, undulation, and direction; means of anchoring or in-situ installation; and bio-enhanced concrete formed by a mixture of cement for marine environments and calcium carbonate (CaCO3) as the manufacturing material by molding.

[0032] According to one embodiment of the invention, these anchoring or in-situ installation means consist of through-holes through which anchor bolts are fixed on site. This facilitates their installation and anchoring in vertical walls using, for example, pneumatic drills, plugs, and stainless steel screws.

[0033] Preferably, this cement for marine environments is a Portland Pozzolanic cement, with a high strength grade for marine environments, for example, a Polpaico 400 cement.

[0034] Preferably, said calcium carbonate (CaCOs) has a size in the range of 50 to 100 pm.

[0035] According to the present invention, the slab comprises a stepped texture on the curved surfaces of the reliefs or grooves of the final slab obtained by a 3D printed mold of the process of the present invention, which delivers a degree of fractal complexity with the grooves or reliefs of the structural heterogeneity present in the slab.

[0036] Structural heterogeneity, according to the present invention, is understood as the capacity of modular slabs to exhibit varying degrees of design complexity, facilitating adaptation to diverse ecological and environmental needs of marine habitats. This heterogeneity is manifested in the incorporation of elements such as grooves or reliefs that vary in direction, length, width, and shape—straight or wavy—to create patterns ranging from simple to highly complex.

[0037] Figures 1 to 3 show, respectively, a slab with structural heterogeneity of simple, medium, and high complexity. Each level of complexity is designed to support different aspects of marine biodiversity and the structural stability of the habitat.

[0038] According to the present invention, said structural heterogeneity comprises: simple complexity by including at least one groove or relief element arranged in at least one direction, of a determined length, straight, and of a constant width, to form a pattern of simple complexity; medium complexity by including at least one groove or relief element arranged in one direction, of a determined length, wavy, and of a variable width, to form a pattern of medium complexity; and high complexity by including at least one groove or relief element arranged in two directions, of a determined length, wavy, and of a variable width, to form a pattern of high complexity.

[0039] Figure 4 presents an arrangement or pattern with a medium complexity slab, shown in Figure 2, where all slabs are arranged in the same orientation.

[0040] Figure 5 presents an arrangement or pattern with said slab of medium complexity, where all the slabs are arranged in either of two opposite orientations.

[0041] Figure 6 shows an arrangement or pattern with the slab of medium complexity, where all the slabs are arranged in any of the four possible orientations. Figure 7 shows an arrangement or pattern with a slab of high complexity, as shown in Figure 3, where all the slabs are arranged in the same orientation.

[0042] Figure 8 presents an arrangement or pattern with said slab of high complexity, where all the slabs are arranged in either of two opposite orientations.

[0043] Figure 9 presents an arrangement or pattern with said slab of high complexity, where all the slabs are arranged in any of the four possible orientations.

[0044] As can be seen in Figures 4 to 9, the modular slabs can be assembled in different directions to produce different designs, depending on the desired complexity of the heterogeneity of the installation site as a whole.

[0045] A manufacturing process for modular slabs for marine structure cladding for the restoration of marine habitats with structural heterogeneity, comprising the following steps: a) designing a computational 3D model, with simple, medium, or high complexity, based on groove or relief characteristics, their quantity, variable width, waviness, and direction; b) including means of anchoring or in-situ installation in the model, such as perforations; c) producing a test mold to produce the 3D model from a computational model of a test mold that includes the inverse 3D model with 3D printing; d) preparing bio-enhanced concrete as a mixture of marine-grade cement with calcium carbonate (CaCO3); e) performing a test of the test mold with the bio-enhanced concrete to manufacture and check the demolding of the slab, and adjust and validate the 3D model;f) produce at least one validated mold from a computational model that includes the inverse of the validated and 3D-printed 3D model; g) produce a plurality of modular slabs with structural heterogeneity of chosen complexity using said at least one validated mold and said bio-enhanced concrete.

[0046] According to the present invention, in step a) a structural heterogeneity is obtained of: simple complexity by including at least one groove or relief element arranged in at least one direction, of a determined length, straight, and a constant width; medium complexity of step a) by including at least one groove or relief element arranged in one direction, of a determined length, wavy, and a variable width; and high complexity of step a) by including at least one groove or relief element arranged in two directions, of a determined length, wavy, and a variable width.

[0047] According to the present invention, in step a) the 3D model can be designed using CAD software, with a simple, medium or high complexity depending on the identification of key species and the evaluation of specific needs of a natural habitat to be restored or produced, promoting biodiversity and protection against adverse environmental conditions.

[0048] According to the present invention, in step d) the bio-enhanced concrete is prepared as a mixture of: marine cement in a proportion of 26 to 29%, aggregates in a proportion of 53 to 56%, water in a proportion of 12 to 15%, and calcium carbonate in a proportion of 3 to 7%. Preferably, in step d), the bio-enhanced concrete is prepared as a mixture of: marine cement in a proportion of approximately 27%, aggregates in a proportion of approximately 54%, water in a proportion of approximately 14%, and calcium carbonate in a proportion of approximately 5%.

[0049] Preferably, in stage d) said cement for marine environment is a Portland Pozzolanic cement, with a high strength grade for marine environments, for example, a Polpaico 400 cement.

[0050] Preferably, in stage d) said calcium carbonate (CaCOs) is obtained from grinding mollusc shells, for example, oyster shells, with a size in the range of 50 to 100 pm.

[0051] Preferably, these mollusc shells are processed by washing to remove salts, dried at room temperature, then ground in a ball mill or similar and finally sieved to separate the fractions between 50 and 100 pm.

[0052] According to the present invention, in step g) manufacturing the plurality of slabs includes curing the slabs by immersion, for at least 7 days, to ensure their hardening and adequate strength.

[0053] According to the present invention, in steps c) and f) the test mold and the validated mold are produced with a flexible plastic material that minimizes adhesion to the bio-enhanced concrete and facilitates demolding, for example, it can be printed with thermoplastic polyurethane (TPU) filament.

[0054] According to the present invention, in step e) adjusting and validating the 3D model may include modifying the grooves or reliefs, including smoothing edges to facilitate demolding.

[0055] Repeat testing to validate the changes made is also contemplated. The production of a series of slabs using the adjusted mold can be considered to verify their performance under real-world conditions. The structural and aesthetic integrity of the produced slabs will be evaluated, and the mold will be approved for large-scale production based on satisfactory mechanical or thermal test results. Figure 10 shows a photograph of thermal tests performed on the slabs of Figures 1 and 3, respectively, which illustrates the heat response of the slabs according to the present invention. The minimum temperature range is 38.3 °C. The maximum temperature range is 66.3 °C. The midpoint of the temperature range corresponds to 52.3 °C; the third quarter of the range corresponds to 59.3 °C; and the first quarter of the range corresponds to 45.3 °C.The simple slab shown in Figure 2 has a temperature of approximately 45°C in the second section, while the surrounding pavement is in the third section with a temperature of approximately 60°C, resulting in a temperature difference of approximately 15°C between the slab and the pavement. The high-complexity slab exhibits an even greater temperature difference with the surrounding pavement; its temperature is estimated to be approximately 40°C in the first section of the thermal test range, resulting in a temperature difference of approximately 20°C between the slab and the pavement.

[0056] Although embodiments of the invention have been illustrated and described in detail in the drawings and description above, such illustration and description should be considered illustrative or exemplary and not restrictive; the invention is not limited to the examples particularly described. Persons skilled in the art understand and can make other variations of the examples particularly described from a study of the drawings, description, and claims. In the specification and claims, the terms "comprising" and "including" are open-ended and do not exclude other elements or steps, and the indefinite article "a" does not exclude a plurality.

Claims

CLAIMS 1.- A modular slab for the cladding of marine structures for the restoration of marine habitats, CHARACTERIZED in that it comprises: a three-dimensional design with a structural heterogeneity with a simple, medium or high complexity, based on characteristics of grooves or reliefs, their quantity, variable width, undulation and direction; means of anchoring or in-situ installation; and bio-enhanced concrete formed by a mixture of cement for marine environment and calcium carbonate (CaCOs) as a manufacturing material by molding.

2. Modular slab according to claim 1, CHARACTERIZED in that said anchoring or in-situ installation means consist of through-holes through which anchor bolts are fixed on site.

3. Modular slab according to claim 1, CHARACTERIZED in that said cement for marine environment is a Portland Pozzolanic cement, with a high strength grade for marine environments.

4. Modular slab according to claim 1, CHARACTERIZED in that said calcium carbonate (CaCOs) has a size in the range of 50 to 100 pm.

5. Modular slab according to claim 1, CHARACTERIZED in that it comprises a stepped texture on the curved surfaces of the reliefs or grooves.

6. Modular slab according to claim 1, CHARACTERIZED in that said structural heterogeneity comprises: a simple complexity by including at least one groove or relief element arranged in at least one direction, of a determined length, straight, and a constant width, to form a pattern of simple complexity; Medium complexity by including at least one groove or relief element arranged in one direction, of a certain length, wavy, and of variable width, to form a pattern of medium complexity; and high complexity by including at least one groove or relief element arranged in two directions, of a certain length, wavy, and of variable width, to form a pattern of high complexity.

7. A manufacturing process for modular slabs for the lining of marine structures for the restoration of marine habitats with structural heterogeneity, CHARACTERIZED in that it comprises the following steps: a) designing a computational 3D model, with a simple, medium or high complexity, based on characteristics of grooves or reliefs, their quantity, variable width, undulation and direction; b) including means of anchoring or in-situ installation in the model such as perforations; c) producing a test mold to produce the 3D model from a computational model of a test mold that includes the inverse 3D model with 3D printing; d) preparing bio-enhanced concrete as a mixture of cement for marine environments with calcium carbonate (CaCO3); e) carrying out a test of the test mold with the bio-enhanced concrete to manufacture and check the demolding of the slab, adjust and validate the 3D model;f) produce at least one validated mold from a computational model that includes the inverse of the validated and 3D-printed 3D model; g) produce a plurality of modular slabs with structural heterogeneity of chosen complexity using said at least one validated mold and said bio-enhanced concrete.

8. The process according to claim 7, CHARACTERIZED in that a structural heterogeneity of: is obtained in step a) simple complexity by including at least one groove or relief element arranged in at least one direction, of a determined length, straight, and a constant width; medium complexity of stage a) by including at least one groove or relief element arranged in one direction, of a determined length, wavy, and a variable width; and high complexity of stage a) by including at least one groove or relief element arranged in two directions, of a determined length, wavy, and a variable width. 9.- The process according to claim 7, CHARACTERIZED in that, in step d), bio-enhanced concrete is prepared as a mixture of: marine environment cement in a proportion of 26 to 29%, aggregates in a proportion of 53 to 56%, water in a proportion of 12 to 15%, calcium carbonate (CaCOs) in a proportion of 3 to 7%. 10.- The process according to claim 7, CHARACTERIZED in that, in step d) of preparing concrete or bio-enhanced concrete as a mixture of: marine environment cement in a proportion of about 27%, aggregates in a proportion of about 54%, water in a proportion of about 14%, calcium carbonate in a proportion of about 5%. 11.- The process according to claim 7, CHARACTERIZED in that, in step d) said marine environment cement is a Portland Pozzolanic cement, with a high strength grade for marine environments. 12.- The process according to claim 7, CHARACTERIZED in that, in step d), said calcium carbonate (CaCOs) is obtained from the grinding of mollusc shells, with a size in the range of 50 to 100 pm. 13.- The process according to claim 12, CHARACTERIZED in that said mollusc shells are processed by washing to remove salts, dried at room temperature, then ground in a ball mill and finally sieved to separate the fractions between 50 and 100 pm. 14.- The process according to claim 7, CHARACTERIZED in that, in step g) manufacturing the plurality of slabs includes curing the slabs by immersion, for at least 7 days. 15.- The process according to claim 7, CHARACTERIZED in that, in steps c) and f) the test mold and the validated mold are produced with thermoplastic polyurethane (TPU) filament. 16.- The process according to claim 7, CHARACTERIZED in that, in step e) adjusting and validating the 3D model, it may include modifying the grooves or reliefs, including smoothing edges to facilitate demolding.

Images