Sustainable generation of large-format precast bioconcrete structures

Abstract

Described herein are methods, reusable frameworks, and systems for producing building materials, structural materials, and concretes. In some cases, a method of producing a construction material is performed including adding a plurality of aggregate particles into a supporting structure, thereby forming a formed plurality of aggregate particles, flowing a fluid comprising cementation reagents through the formed plurality of aggregate particles, reacting the cementation reagents with a biological organism or an enzyme within the fluid or within the formed plurality of aggregate particles for a sufficient time to consolidate or bind at least a portion of the formed plurality of aggregate particles, thereby producing the construction material.

Description

Docket No.: BMI-1016PCTSUSTAINABLE GENERATION OF LARGE-FORMAT PRECAST BIOCONCRETE STRUCTURESCLAIM OF PRIORITY

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 726,475, filed November 29, 2024, which is herein incorporated by reference in its entirety.RIGHTS IN THE INVENTION

[0002] This invention was made with government support under W5170L24-C-0029 awarded by the Small Business Innovation Research Contracting Center of Excellence. The government has certain rights in the invention.BACKGROUND

[0003] Biocement technologies offer cost effective high-strength building materials, structural materials, and concretes which can have a substantially reduced carbon emission footprint compared to traditional building materials and concretes. Accordingly, methods, reusable frameworks, and systems of producing building materials, structural materials, and concretes in various shapes are needed for different construction purposes and applications.BRIEF SUMMARY

[0004] Biocement technologies utilize biology (e.g., enzymes or microorganisms) to improve the mechanical and structural properties of construction materials. In some cases, through microbiologically induced calcium carbonate precipitation (MICP), microorganisms react with chemical components to produce minerals in the form of organic-inorganic compounds that act as binding agents within a construction material, such as construction aggregate that includes particles of sand, gravel, and crushed stone. Aggregate particles may comprise inert granular materials such as sand, gravel, or crushed stone.

[0005] During conventional precast concrete manufacturing, pre-mixed concrete is poured as a slurry into a wood or steel framework where it cures until the concrete is strong enough for the framework to be removed. During bioconcrete manufacturing, a mixture of aggregate particles and bacteria is created prior to or while the mixture is packed into a framework. A mixture of urea, calcium salts, and nutrients may then be pumped into or flowed through the framework using a feeding and pumping system to induce formation of calcium carbonate cement within the mixture to bind the aggregate particles together.Docket No.: BMI-1016PCT

[0006] In some embodiments, microorganism or enzyme-based biocementation and construction material production systems include pressure-based feeding systems to manufacture construction materials. In some embodiments, a microorganism or enzyme-based construction material production system utilizes bacteria to form calcium carbonate cement that acts as a binding agent to bind aggregate particles (e.g., sand and gravel) to form bioconcrete. The microorganism or enzyme-based construction material production system may convert liquid feedstock containing urea, calcium salts (e.g., calcium chloride or other calcium2+- containing salts), and nutrients into the biocement using a biocementation reaction. The microorganism or enzyme-based construction material production system may be used to manufacture large-format precast bioconcrete structures and large-format sustainable construction materials. The precast bioconcrete structures may include L-wall barriers, Jersey barriers or other barrier-style traffic barriers, non-load bearing wall panels, load bearing wall panels, breakwater unit structures, culvert units, blast walls (e.g., to protect vulnerable buildings or areas from nearby explosions), and T-walls. T-walls of sufficient size may provide blast protection. For example, a T-wall may be manufactured that is at least 9” thick and 128” tall with a 39” foot.

[0007] Use of Reinforcement Materials

[0008] In some cases, the strength and resiliency of bioconcrete structures are improved by utilizing reinforcement structures and materials within the bioconcrete structures. In one example, a reinforcement structure comprises a rebar mesh structure contained within or integrated with a bioconcrete structure. The reinforcement structure increases the flexural strength of the bioconcrete structure and / or increases tire resistance to bending forces. The reinforcement structure may comprise various forms, such as rods and meshes. In one example, the reinforcement material includes rebar (e.g., steel rebar) to increase the tensile strength of a bioconcrete structure to reduce crack sizes and failure in areas of tension. However, rebar corrosion or breakdow n, initiated by exposure to water, carbon dioxide, calcite, or chloride, may lead to spalling and failure of reinforced structures, which may reduce tire usable lifetime and strength of the bioconcrete structure.

[0009] Rebar may refer to a metal rebar or a non-metal rebar.

[0010] In some cases, the reinforcement material comprises coated rebar, coated metal rebar, coated steel rebar, and coated non-steel materials, such as coated fiber reinforced polymer rebar. In one embodiment, the reinforcement material comprises epoxy coated rebar, epoxycoated steel rebar, or polymer coated rebar. In another embodiment, the reinforcement material comprises coated rebar that is coated with basalt fibers covering the rebar. In someDocket No.: BMI-1016PCT embodiments, the reinforcement material comprises a basalt fiber composite rebar (e.g., basalt fiber polymer composite, e.g., basalt fiber-epoxy composite). In some embodiments, the reinforcement material comprises basalt coated rebar or sand coated rebar. In some embodiments, the reinforcement material comprises basalt fibers in a polymer composite (e.g., basalt fibers held together in an epoxy resin) which may further include a coating (e.g., of sand, basalt fibers, epoxy resin, a lacquer, or a combination thereof). One potential issue with utilizing uncoated rebar is that rusting of the rebar may be induced during feeding with calcium chloride. Thus, coated rebar may extend the usable lifetime and strength of the underlying rebar. Moreover, utilization of coated rebars (e.g., epoxy-coated rebar) may improve bonding or adhesion between the reinforcement material and biocement. In some cases, epoxy-coated rebar has better bonding and / or adhesion with the biocement matrix compared to uncoated rebar, such as steel rebar, basalt rebar, or fiberglass rebar.

[0011] The surface of the coating may be sand-coated, roughened, or otherwise made less smooth to improve adhesion between the rebar and the biocement matrix. In one embodiment, the coating around the rebar may include sand or fibers to improve adhesion with the biocement matrix. The fibers may include glass fibers or basalt fibers. In another embodiment, the coating around the rebar may include an additional adhesion layer that includes sand. In another embodiment, a composite rebar (e.g., fiberglass rebar, basalt rebar, etc.) may include sand as a component (e.g.. so that sand particles protrude from the surface and act as nucleation sites for biocementation).

[0012] Pressurized Non-Recirculatory and / or Pulsed Feeding of Shaped Aggregate to Manufacture Large-Format Precast Construction Materials

[0013] A biocementation system may manufacture precast biocement structures within a framework that holds and forms aggregate particles into a particular shape. The framework may comprise part of a pressurized feeding system in which recycled or unrecycled feed solution is flowed through the shaped aggregate particles such that the shaped aggregate particles are consolidated and hardened into a construction material with the particular shape. The biocementation system may be plumbed with feedstock delivery lines in which biologies and feedstock solutions (or feed solutions) are not recirculated through the aggregate-filled framework. In a pressurized feeding system, pressurized non-recirculatory (e.g., without continuous recirculation of the feed solution) and / or pulsed feeding may be performed in which unrecycled or recycled feed solution is periodically pumped through a framework. A feed cycle may correspond to application of a particular feed volume of the feed solution (e.g.. a volume of liquid comprising 15 gallons of a feed solution) to the shaped aggregate particles within theDocket No.: BMI-1016PCT framework over a particular period of time (e.g., over a ten-minute time period). A single-use or single -pass feed cycle may refer to the application of a particular feed volume of the feed solution in which the feed solution applied is not reapplied during subsequent feed cycles. During single-use or single-pass feed cycle, the feed solution delivered to the aggregate particles is not reused. The biocementation system may utilize pressurized non-recirculatory and / or pulsed feeding in which feed cycles are periodically performed (e.g., on an hourly basis or every four hours, or e.g., on a timed basis based on a time known or predicted to correspond to consumption of 50-100% (e.g., about 60%, 65%, 70%, 75% 80%, 85%, 90%, or 95%, or e.g., from 60% to 80%, from 70% to 95%, from 80% to 100%, etc.) of one or more cementation reagents in a pulse volume). In one example, a first feed cycle lasting ten minutes is followed by a four-hour growing time, then followed by a second feed cycle lasting ten minutes followed by a four-hour growing time. In some cases, the length of the growing time (e.g., between 1 and 5 hours) may vary depending on the biocementation reaction rate. Pulses in a pressurized unrecycled feeding system may include multiple pulses of a single-pass feed solution that is not recycled back into tire framework. Pulsed feeding may also be advantageous in a recirculating (e.g., recycled) feed system.

[0014] Preheating Aggregate Prior to Pressurized Feeding

[0015] As the biocementation system may manufacture biocement structures in an outdoor environment in which temperatures may fall below freezing or be below a threshold temperature (e.g., arc below 10 degrees Celsius), tire bioccmcntation system may preheat the aggregate particles prior to inserting tire aggregate particles into the framework or prior to performing one or more feed cycles to the aggregate particles. In some embodiments, the biocementation system may preheat the aggregate particles to between 10 degrees Celsius and 40 degrees Celsius. In some embodiments, the biocementation system may preheat the aggregate particles to between 20 degrees Celsius and 35 degrees Celsius.

[0016] In some cases, the biocementation system may preheat the aggregate particles using a heated mixer, a jacketed mixer that mixes hot fluid (e g., hot water, hot air, etc.) with the aggregate particles, one or more heat lamps, or bathing the aggregate particles in a bath of hot water or water at a temperature above 25 degrees Celsius. The aggregate particles may be heated or temperature regulated by arranging the aggregate particles within a staging area w ith warm air or a temperature-controlled environment. The aggregate particles may be heated or cooked using microwaves (e.g., using a conveyor belt to move the aggregate particles into and from an industrial-sized microwave oven). A benefit of preheating or cooking the aggregate particlesDocket No.: BMI-1016PCT prior to pressurized feeding is that bad microbes (e.g., adventitious or deleterious native microbes) may be eliminated prior to performance of feed cycles.

[0017] Use of Vibratory Packing of Aggregate Particles

[0018] One issue with utilizing reinforcement structures and materials within bioconcrete structures is that packing or compaction of aggregate particles during manufacturing may be negatively impacted by tire presence of the reinforcement structures and materials.

[0019] A pressure-fed biocementation system may utilize vibratory packing prior to feed cycles, or during feed cycles and / or growth cycles to increase the density of precast construction materials. The aggregate particles may be arranged within a vibratory press (e.g., tire framework which shapes the aggregate and contains the fluid flow may contain an element that applies both pressure and vibration) that applies pressure and vibration to reduce tire volume of empty space between the aggregate particles. In some cases, a panel of a framework or a portion of a framework may be mechanically or acoustically coupled to a vibratory element. In some cases, sounds waves or ultrasonication techniques may be applied to tire aggregate particles prior to and / or during feed cycles. Sonic vibration during packing is advantageous for allowing dense packing of non-standard shapes and when rebar is used which may interfere with packing in one or more directions. In some embodiments, an acoustic or mechanical vibratory element is mechanically or acoustically coupled to a network of rebar in the aggregate. In one embodiment, vibratory packing may be utilized until the aggregate particles reach a particular green density range. In one example, vibratory packing may be utilized until the aggregate particles have a green density greater than 1.8 grams per cubic centimeter (g / cc) or a green density range between 1.8 g / cc and 2.4 g / cc.

[0020] A biostructure may comprise a structure or construction material that is constructed using one or more biological processes (e.g., using an enzyme or microorganism). A construction material that is constructed using one or more biological processes may comprise a living construction material if the resulting construction material includes living microorganisms. A construction material that is the result of the application of one or more biological processes may or may not include living biological materials or microorganisms. A construction material that is the result of the application of one or more biological processes may or may not include the remains of biological materials or microorganisms (e.g., entombed cells (e.g., in calcite), or cavities left by the disintegration thereof).

[0021] According to some embodiments, the technical benefits of the systems and methods of manufacturing biostructures disclosed herein include reduced manufacturing time, reducedDocket No.: BMI-1016PCT manufacturing costs, significantly reduced energy footprint for manufacturing, increased construction material throughput, improved freeze-thaw properties, increased flexural strength for the construction material, higher densities, lower porosities, and increased compressive strength for the construction material.

[0022] A particular technical benefit of the methods and systems described herein is that many complicated and non-standard 3D shapes are possible, for example, angled shapes such as L-barriers and T-walls, artistically molded shapes, spheroids, star-like shapes, etc. Further, the methods and systems described herein permit the manufacture of construction units that are considerably larger than structural units previously demonstrated in MICP-based technologies.

[0023] Technical benefits of manufacturing construction materials with reinforcement structures or materials (e.g., coated rebar reinforcement), manufacturing construction materials utilizing vibratory' packing of aggregate particles during feed and / or growth cycles, manufacturing construction materials with preheated aggregate prior to pressurized feeding, and manufacturing construction materials with pressurized non-recirculatory and / or pulsed feeding of shaped aggregate include improved freeze-thaw properties, increased flexural strength for the construction material, higher densities, lower porosities, and increased compressive strength for the construction material.

[0024] One technical issue with producing complex shapes using a biocementation process with pressurized feeding, e.g., processes requiring delivery of reagents to reactive sites inside pores from outside of the form, is that elements of the shape (and corresponding volumes within the framework), for example, protrusions, cavities, convexities, etc., may result in air gaps, or regions of low cementation reagent flow, resulting in inconsistency of tire finished product. Pluralities of inlets and / or outlets in a framework, in combination with pumped flow to supply cementation reagents solve this problem and permit the production of a broad variety of complex shapes.

[0025] In some embodiments, the construction material produced has a compressive strength of at least about 3000 psi (e.g., at least 4000 psi, or at least 6000 psi), and / or wherein the construction material remains undamaged after 25 cycles of an EN 14617-5 freeze / thaw test. In some embodiments, a bioconcrete construction material produced by the methods or systems described herein has a compressive strength of about 900 psi to about 12,000 psi. In some embodiments, a bioconcrete 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,Docket No.: BMI-1016PCT 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 1,200 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 1,800 psi to about 2,000 psi, about 1,800 psi to about 2,500 psi, about 1,800 psi to about 3,000 psi, about 1,800 psi to about 3,500 psi, about 2,000 psi to about 2,500 psi, about 2,000 psi to about 3,000 psi, about 2,000 psi to about 3,500 psi, about 2,500 psi to about 3,000 psi, about 2,500 psi to about 3,500 psi, or about 3,000 psi to about 3,500 psi, about 1,100 psi to about 4,200 psi, about 2,100 psi to about 4,300 psi, about 2,100 psi to about 5,400 psi, about 2,100 psi to about 5,600 psi, about 2,100 psi to about 4,800 psi, about 2.100 psi to about 8,000 psi, about 1.100 psi to about 7,500 psi, about 4,100 psi to about 10,000 psi, about 5,100 psi to about 11,500 psi, about 6,200 psi to about 7,300 psi, about 5,200 psi to about 9,400 psi, about 6,200 psi to about 9,600 psi, about 5,200 psi to about 11,800 psi, about 1,200 psi to about 10,000 psi, about 2,000 psi to about 10,000 psi, about 3,000 psi to about 10,000 psi, about 4,000 psi to about 10,000 psi, about 5,000 psi to about 10,000 psi, about 6,000 psi to about 10,000 psi, about 7,000 psi to about 10,000 psi, about 8,000 psi to about 10,000 psi, about 9,000 psi to about 10,000 psi, or about 10,200 psi to about 12,000 psi. In some embodiments, a bioconcrete construction material has a compressive strength of about 1.000 psi, about 2,000 psi, about 3,000 psi, about 4,000 psi, about 5,000 psi, about 6,000 psi, about 7,000 psi, about 8,000 psi, about 9,000 psi, about 10,000 psi, about 11,000 psi, or about 12,000 psi. In some embodiments, a bioconcrete construction material has a compressive strength of at least 900 psi, 1,000 psi, 2,000 psi, 3,000 psi, 4,000 psi, 5,00 psi, 6,000 psi, 7,000 psi, 8,000 psi, 9,000 psi, 10,000 psi, 11,000 psi, or 12,000 psi.

[0026] In some embodiments, one or more cementation reagents (e.g., one or more enzymes, organisms, urea, etc.) are added to a plurality of aggregate particles prior to tire aggregate being added to a framework or supporting structure. The one or more cementation reagents may be added during mixing / blending of the aggregate (e.g., in a cement mixer or other mixing device). While in a supporting structure (e.g., a framework), the plurality of aggregate particles may be inoculated with microorganisms using a feeding or pumping system.

[0027] In some embodiments, a method of producing a construction material is performed including adding a plurality of aggregate particles into a supporting structure, thereby forming a formed plurality of aggregate particles, and then flowing a fluid comprising cementation reagents through tire formed plurality of aggregate particles. In some cases, the method further comprises reacting the cementation reagents with a biological organism or an enzyme withinDocket No.: BMI-1016PCT the fluid or within the formed plurality of aggregate particles for a sufficient time to consolidate or bind at least a portion of the formed plurality of aggregate particles, thereby producing the construction material.

[0028] This Summary is provided to introduce a brief description of some aspects of the disclosed technologies in a simplified fonn that 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. Furthermore, the claimed subject matter is not limited to implementations that solve any or all disadvantages noted in any part of this disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Features and advantages of the present disclosure will be obtained by reference to the following description that sets forth illustrative embodiments, in which the principles of the disclosure are utilized, and the accompanying drawings of which:

[0030] FIGS. 1A-1B shows a 7-unit paver framework that is used to make the paver. FIG.1A shows the top view of the framework when the aggregate blend was being packed into the mold. FIG. IB shows the top plenum and one side removed after the packing was completed.

[0031] FIG. 2 illustrates a feeding scheme for producing the pavers.

[0032] FIG. 3A illustrates the locations of the samples cut from the paver and the results of each test.

[0033] FIGS. 3B-3C depict compressive strength and flexural strength test results.

[0034] FIGS. 4A-4B illustrate a framework used for making approximately 100 sq. ft. of a precast article. FIG. 4A illustrates the top and bottom plenum of the panel mold. FIG. 4B illustrates an exploded view of a system for producing pavers.

[0035] FIGS. 5A-5B show a framework used for making an L-wall barrier. FIG. 5A shows the L-wall barrier framework design. FIG. 5B shows the final L-wall barrier product.

[0036] FIG. 6 shows tire final modular wall panel product.

[0037] FIGS. 7A-7B show a final jersey barrier product and the fiberglass rebar element within the jersey barrier mold.

[0038] FIGS. 8A-8B show a pillar framework and the fiberglass rebar element before inserting into the pillar mold.Docket No.: BMI-1016PCT

[0039] FIG. 8C shows silicone mold (top) removing from the surface of the final product (bottom).

[0040] FIG. 9A depicts one embodiment of a biocementation system for manufacturing a construction material using one or more biocementation processes.

[0041] FIG. 9B depicts one embodiment of various components of a computing system.

[0042] FIGS. 9C-9H depict embodiments related to various systems and processes for manufacturing a construction material.DETAILED DESCRIPTION

[0043] All terms are intended to be understood as they would be understood by a person skilled in the art. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary' skill in the art to which the disclosure pertains.

[0044] The following definitions supplement those in the art and are directed to the current application and are not to be imputed to any related or unrelated case, e.g., to any commonly owned patent or application. Although any methods and materials similar or equivalent to those described herein can be used in the practice for testing of the present disclosure, the preferred materials and methods are described herein. Accordingly, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0045] The terminology used herein is for the purpose of describing particular cases only and is not intended to be limiting. In this application, the use of die singular includes the plural unless specifically stated otherwise. As used herein, the singular forms “a”, "an" and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0046] The term “about” or “approximately” can mean within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, i.e., the limitations of the measurement system. For example, “about” can mean within 1 or more than 1 standard deviation, per the practice in the art. Alternatively, “about” can mean a range of up to 20%, up to 15%, up to 10%, up to 5%, or up to 1% of a given value. Alternatively, particularly with respect to biological systems or processes, the term can mean within an order of magnitude, within 5-fold, or within 2-fold, of a value. Where particular values are described in the application and claims, unless otherwise stated the term “about” meaning within an acceptable error range for the particular value should be assumed.Docket No.: BMI-1016PCT

[0047] As used in this specification and claim(s), the words "comprising" (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps. It is contemplated that any embodiment discussed in this specification can be implemented with respect to any method or composition of the present disclosure, and vice versa. Furthermore, compositions of the present disclosure can be used to achieve methods of the present disclosure.

[0048] Reference in the specification to “some embodiments,” “an embodiment,” “one embodiment” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with tire embodiments is included in at least some embodiments, but not necessarily all embodiments, of the present disclosures. To facilitate an understanding of the present disclosure, a number of terms and phrases are defined below.

[0049] Ranges provided herein are understood to be shorthand for all of the values within the range. For example, a range of 1 to 50 is understood to include any number, combination of numbers, or sub-range from the group consisting of 1, 2, 3, 4, 5. 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50, as well as all intervening decimal values between the aforementioned integers such as, for example, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, and 1.9. With respect to sub-ranges, “nested sub-ranges” that extend from either end point of the range are specifically contemplated. For example, a nested sub-range of an exemplary range of 1 to 50 may comprise 1 to 10, 1 to 20, 1 to 30, and 1 to 40 in one direction, or 50 to 40, 50 to 30, 50 to 20, and 50 to 10 in the other direction.

[0050] The term “optional” or “optionally” denotes that a subsequently described event or circumstance can but need not occur, and that the description includes instances where the event or circumstance occurs and instances in which it does not.

[0051] Certain embodiments herein contemplate numerical ranges. When ranges are present, the ranges include the range endpoints. Additionally, every sub range and value within the range is present as if explicitly written out. The term “about”, “approximately”, or “substantially” may mean within an acceptable error range for the particular value, which may depend in part on how the value is measured or determined, e.g., the limitations of tire 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. Where particular values are described in theDocket No.: BMI-1016PCT application and claims, unless otherw ise stated the term “about” meaning within an acceptable error range for the particular value may be assumed.

[0052] As used herein, the term “construction material” or “construction materials” generally refers to an article which comprises elements or subcomponents that are bound together by cement linkages or bridges of adhesive properties. The linkages or bridges of the construction material may be calcium carbonate. Construction materials as used herein are individual physical objects of a defined shape that can be incorporated into a building, a structure, or a work. In particular, construction materials used herein comprise biocement products. Examples of biocement products include, but are not limited to, items made from bioconcrete, biocement coated aggregates, and tire like.

[0053] As used herein, the term “bridging calcium carbonate” generally refers to calcium carbonate that is between, connects with, and / or contributes to the binding together of at least two moieties, such as aggregate particles. Together with the at least two moieties, the bridging calcium carbonate provides for a continuous piece comprising the at least two moieties and the bridging calcium carbonate. The calcium carbonate may be a solid, such as a precipitate. The calcium carbonate may be formed from the reaction of calcium ions with carbonate ions in aqueous solution, wherein the resulting calcium carbonate is integrated into a bulk composite material comprising calcium carbonate and the aggregate particles. Calcium carbonate that does not bridge or connect two pieces of aggregate can still be considered bridging if it contributes to tire strength of the overall binding, c.g., by further structurally reinforcing a bridging or connecting piece of calcium carbonate that it is attached to either directly or indirectly.

[0054] As used herein, tire term “non-bridging calcium carbonate” generally refers to calcium carbonate that does not connect with or contribute to tire binding together of at least two moieties, such as aggregate particles. The non-bridging calcium carbonate may be a precipitate that connects with only one moiety, such as an aggregate particle, or a precipitate that does not connect with any aggregate particle. The non-bridging calcium carbonate may be bound to at most one moiety.

[0055] As used herein, the term “aggregate particles” generally refers to components of a cement that may be bound together according to the disclosures herein, such as the compositions, systems, and methods herein. Aggregate particles may comprise materials used as described herein and / or in masonry, such as those a person of skill in the art would use.

[0056] As used herein, the terms “aggregate” or “aggregate particles” may be used interchangeably and generally refer to any type of particulate matter which can be boundDocket No.: BMI-1016PCT together into larger particles or consolidated solids by biocement bonds or bridges. Nonlimiting examples of aggregates include fine-grained aggregate (e.g., sand), coarse-grained aggregate (e.g., gravel), crushed stone (which may be ultrafine, fine, or coarse-grained), mine tailings, or combinations thereof, etc.

[0057] In some embodiments, fine grain limestone particles may be used in place of pond fines within the construction material. An aggregate mix may include a mixture of sand, gravel, crushed stone, and / or fine grain limestone particles that have diameters less than 250 micron or less than 100 micron. The fine grain limestone may have a mean particle diameter (or greatest cross-sectional dimension, or smallest cross-sectional dimension) of less than 250 micron, e.g., between 1 micron and 250 micron (e.g., between 1 micron and 2 micron, betw een 1 micron and 5 micron, betw een 2 micron and 4 micron, between 2 micron and 3 micron, betw een 1 micron and 10 micron, between 2 micron and 10 micron, between 5 micron and 10 micron, between 1 micron and 20 micron, between 10 micron and 20 micron, between 1 micron and 100 micron, between 10 micron and 100 micron, between 1 micron and 50 micron, between 15 micron and 25 micron, between 20 micron and 40 micron, between 20 micron and 50 micron, between 25 micron and 50 micron, between 50 micron and 100 micron, between 30 micron and 100 micron, between 40 micron and 80 micron, between 25 micron and 75 micron, between 50 micron and 150 micron, betw een 75 and 150 micron, between 80 and 120 micron, between 125 micron and 225 micron, betw een 150 micron and 250 micron, between 175 micron and 225 micron, between 180 micron and 220 micron, between 200 micron and 220 micron, or betw een 200 and 250 micron) e.g., less than 225 micron (e.g.. less than 200 micron, less than 150 micron, less than 100 micron, less than 50 micron, less than 20 micron, less than 10 micron, less than 5 micron, or less than 2 micron) e.g., about 1 micron, about 2 micron, about 5 micron, about 10 micron, about 15 micron, about 20 micron, about 30 micron, about 40 micron, about 50 micron, about 60 micron, about 70 micron, about 80 micron, about 90 micron, about 100 micron, about 120 micron, about 150 micron, about 175 micron, about 200 micron, about 220 micron, or about 250 micron. The fine grain limestone may have a median particle diameter (or greatest cross- sectional dimension, or smallest cross-sectional dimension) of less than 250 micron, e.g., between 1 micron and 250 micron (e.g., between 1 micron and 2 micron, between 1 micron and 5 micron, between 2 micron and 4 micron, between 2 micron and 3 micron, between 1 micron and 10 micron, betw een 2 micron and 10 micron, betw een 5 micron and 10 micron, between 1 micron and 20 micron, between 10 micron and 20 micron, between 1 micron and 100 micron, between 10 micron and 100 micron, betw een 1 micron and 50 micron, between 15 micron and 25 micron, between 20 micron and 40 micron, between 20 micron and 50 micron, between 25 micron and 50 micron, between 50 micron and 100 micron, between 30 micron and 100 micron,Docket No.: BMI-1016PCT between 40 micron and 80 micron, between 25 micron and 75 micron, between 50 micron and 150 micron, between 75 and 150 micron, between 80 and 120 micron, between 125 micron and 225 micron, between 150 micron and 250 micron, between 175 micron and 225 micron, between 180 micron and 220 micron, between 200 micron and 220 micron, or between 200 and 250 micron) e.g., less than 225 micron (e.g., less than 200 micron, less than 150 micron, less than 100 micron, less than 50 micron, less than 20 micron, less than 10 micron, less than 5 micron, or less than 2 micron) e.g., about 1 micron, about 2 micron, about 5 micron, about 10 micron, about 15 micron, about 20 micron, about 30 micron, about 40 micron, about 50 micron, about 60 micron, about 70 micron, about 80 micron, about 90 micron, about 100 micron, about 120 micron, about 150 micron, about 175 micron, about 200 micron, about 220 micron, or about 250 micron. In some embodiments, tire fine grain limestone may have a particle size distribution in which 100%, 90%, 80%, 75%, 70%, 60%, 50%, 40%, 30%, 25%, 15%, or 10% of the particles are smaller than 20 micron. The fine grain limestone may have a particle size distribution in which 100% of the particles pass through a mess of with a mesh size of 2000 micron, 125 micron, 63 micron, or 45 micron. The fine grain limestone may have a particle size distribution in which 99% of the particles pass through a mess of with a mesh size of 250 micron, or 20 micron, or 10 micron. The fine grain limestone may have a particle size distribution in which 97% of the particles pass through a mess of with a mesh size of 125 micron, or 63 micron, or 10 micron. The fine grain limestone may have a particle size distribution in which 50% of the particles pass through a mess of with a mesh size of 2 micron. The fine grain limestone may have a particle size distribution in which 18% of the particles pass through a mess of with a mesh size of 1 micron. The fine grain limestone may have a Mohs hardness of between 2 and 4 (e.g., 2-2.2, 2-2.4, 2-2.5, 2.2.6, 2-2.8, 2-2.9, 2-3, 2-3.2, 2.2-3.2, 2.5-3.5, 2.5-3, 2.8-3.8, or 3-4, e.g., about 2.2, 2.5, 2.7, 2.8, 3, 3.2, 3.5, or 4). The fine grain limestone may have a porosity of from 0. 1% for the to 40% (e.g., from 0. 1 to 1%, from 1% to 10%, from 10% to 40%, e.g.. from 20% to 40%, from 25% to 40%, from 30% to 40%. from 35% to 40%, or from 38% to 40%. Alternative fine-grained components, e.g., having particle size distributions as described herein, may include Wollastonite, Bentonite, gypsum (e g., plaster of Paris), pond fines, pozzolans (e.g., fly ash or volcanic pozzolans), etc. Some fine-grained aggregate components may also act as binders (e.g., in place of a gelling agent such as cornstarch).

[0058] As used herein, tire term ‘’cementation reagents” generally refers to any combination of starting materials, which when combined and allowed to react produce a binding agent via a biological mechanism. For example, cementation reagents in a urea-hydrolysis based biocementation system may comprise urea (or another suitable nitrogen source which may or may not be converted to urea in-situ, e.g., by urea-producing microorganisms, as described inDocket No.: BMI-1016PCTU.S. Patent No. 11,518,687 the contents of which is herein incorporated by reference in its entirety), a soluble calcium source (e.g., calcium chloride, calcium acetate, calcium phosphate, calcium sulphate, calcium lactate, calcium nitrate, etc.). Cementation reagents may also include an enzyme (or an organism containing or expressing an enzyme) can lead to the enzymatic formation of a biocement, such as calcium carbonate, which binds together adjacent aggregate particles. The cementation reagents may also include nutrients which promote urease activity (which may vary depending on whether pure enzyme or urease-producing cells are used), and urease to form and precipitate a calcium carbonate biocement. In a calcium carbonate based biological sintering biocementation system (e g., one including features as described in International Application No. PCT / US2020 / 018646 published 20 Aug. 2020 the contents of which is herein incorporated by reference in its entirety), examples of biocementation reagents can comprise calcium carbonate, e.g., in combination with other cementation reagents (e.g., enzymes, organisms, substrates, nutrients, etc.) which promote enzymatic acid production, e.g., an acid producing enzyme and substrates therefore (e.g., sugars), which generates acid (i.e., a pH drop) to dissolve the calcium carbonate. Biocementation reagents for such a system may also comprise a second set of nutrients and a second enzyme which together promote a pH increase, reprecipitating calcium carbonate to fonn a biocement.

[0059] As used herein, tire terms “produce,” “production,” and “producing” regarding calcium carbonate in the presence of an enzyme or a biological organism refer to the biological reactions enabled by the enzyme or the biological organism to produce tire conditions to fonn calcium carbonate from starting materials such as calcium ion. carbonate ion, or other possible chemical entities. For example, an enzyme, which produces carbonate ion or calcium ion, can be called an enzyme producing calcium carbonate. An enzyme, which causes pH changes to enable the precipitation of calcium carbonate, can also be called an enzyme producing calcium carbonate.

[0060] As used herein, the term “framework” means any structure into which aggregate can be added which imposes a shape on the aggregate. In some cases, a framework comprises a formwork or supporting structure. In some cases, a framework comprises a mold (e.g., a cast, a die, a form, or a container) into which the aggregate is inserted. A framework may include one or more inlets and / or one or more outlets. The one or more inlets and / or one or more outlets allow fluid and air flow to interact with aggregate particles within the framework. An outlet in a framework may be an entirely open surface (e g., an open top) or a hole within the framework that allows for fluid flow’ or gas flow' from the framework.Docket No.: BMI-1016PCT

[0061] In some cases, a supporting structure is used to impose a shape on aggregate particles contained within the supporting structure. The supporting structure may fully enclose the aggregate particles or partially enclose the aggregate particles supported by the supporting structure. In one example, the supporting structure is a container with an open top. In another example, the supporting structure is mold or rigid mold that includes holes.

[0062] As used herein, the term Microbiologically 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. The at least one enzyme or biological organism can form either calcium ion or carbonate ion, or can change the pH of the environment to precipitate the calcium carbonate. In the methods described herein, MICP may also produce carbonates of other metals, which may or may not be incorporated into the bridging calcium carbonate.

[0063] The construction materials described herein can take many different forms and shapes. An example construction material, such as a unit (e.g., a brick, tile, or paver) with a top surface, four vertical sides and a bottom surface, may be used to illustrate the many features of the disclosed embodiments. However, the construction materials are not limited to only cubiform. In one example, a construction material may comprise a tile, such as a round tile with a top surface, a vertical circular side, and a bottom. In another example, a unit may be formed (e.g., pressed) in a mold or formwork that gives it one or more curved faces, edges, or vertices.

[0064] As used herein, the unit “g / cc” generally refers to the unit grams per cubic centimeter (g / ern3), which is a unit for density. The percentage of void within a portion of a construction material may correspond to an average porosity for the portion of the construction material.

[0065] The aggregate material may comprise rock (e.g., fines), sand, glass, wood, paper, metal, plastic, polymers, minerals, manufacturing or processing waste materials such as ash, carbon, or wood residuals, any of which can be crushed or used whole or combinations thereof.

[0066] The aggregate material may comprise organic or inorganic material such as, for example, sand, rock, glass (e g., Poraver), wood, paper, metal, plastic, polymers, minerals, recycled materials, or combinations thereof. Aggregate particles may comprise beads, grains, rods, strands, fibers (e.g.. fiberglass, basalt fibers, jute fibers, polymer (e.g., polyethylene or polypropylene) fibers, etc.), flakes, crystals, pulverized or crushed materials, or combinations thereof. The construction material may comprise bricks, thin bricks, pavers, panels, tile, veneer,Docket No.: BMI-1016PCT cinder, breeze, besser, clinker or aerated blocks, counter- or table-tops, design structures, blocks, a solid masonry structure, piers, foundations, beams, walls, slabs, or combinations thereof.

[0067] Construction Material

[0068] Provided in various embodiments herein is a construction material produced by any method, reusable framework, or system described herein.

[0069] Construction material can also take many different forms and shapes. In some embodiments, tire forms and / or shapes of the construction material can be generated by any suitable mold cavity inside of a framework producing a construction material. In some embodiments, a mold cavity can be a brick shape. Therefore, construction material can be a unit or a brick with a top surface, four vertical sides and a bottom surface. However, the construction materials are not limited to the brick form only. For example, another example construction material can be a round tile with a top surface, a vertical circular side, and a bottom.

[0070] In some embodiments, a construction material comprises a paver. In some embodiments, a construction material comprises a plurality of pavers. In some embodiments, a construction material comprises an L-wall. In some embodiments, a construction material comprises a wall panel. In some embodiments, a construction material comprises a modular wall panel. In some embodiments, a construction material comprises jersey barrier. In some embodiments, a construction material comprises a pillar.

[0071] In some embodiments, any construction material described herein comprises any suitable concrete construction material. In specific embodiments, a concrete construction material comprises any suitable bioconcrete construction material. In some embodiments, a construction material comprises any suitable precast concrete construction material. In some embodiments, a construction material comprises any suitable precast bioconcrete construction material.

[0072] In some embodiments, any construction material described herein has a compressive strength of at least about 3000 psi (e.g., at least 4000 psi, or at least 6000 psi), and / or wherein the construction material remains undamaged after 25 cycles of an EN 14617-5 freeze / thaw test. In some embodiments, any construction material described herein has a compressive strength of at least about 3000 psi (e.g., at least 4000 psi, or at least 6000 psi), and wherein tire construction material remains undamaged after 25 cycles of an EN 14617-5 freeze / thaw test. In some embodiments, any construction material described herein has a compressive strength of at least about 3000 psi (e.g., at least 4000 psi, or at least 6000 psi), or wherein the construction material remains undamaged after 25 cycles of an EN 14617-5 freeze / thaw test. In someDocket No.: BMI-1016PCT embodiments, any construction material described herein has a compressive strength of at least about 3000 psi (e.g., at least 4000 psi, or at least 6000 psi). In some embodiments, any construction material described herein remains undamaged after 25 cycles of an EN 14617-5 freeze / thaw test.

[0073] In some embodiments, any construction material described herein has a compressive strength of at least about 3000 psi (e.g.. at least 4000 psi, or at least 6000 psi). In some embodiments, any construction material described herein has a compressive strength of at least about 4000 psi. In some embodiments, any construction material described herein has a compressive strength of at least about 6000 psi. In some embodiments, any construction material described herein has a compressive strength of at least about 8000 psi. In some embodiments, a bioconcrete construction material produced by the methods or systems described herein has a compressive strength of about 900 psi to about 12,000 psi. In some embodiments, a bioconcrete 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 about1.200 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 1.800 psi to about 2,000 psi, about 1.800 psi to about 2,500 psi, about 1,800 psi to about 3,000 psi, about 1,800 psi to about 3,500 psi, about 2,000 psi to about 2,500 psi, about 2,000 psi to about 3,000 psi, about 2,000 psi to about 3,500 psi, about 2,500 psi to about 3,000 psi, about 2,500 psi to about 3,500 psi, or about 3,000 psi to about 3,500 psi, about 1,100 psi to about 4,200 psi, about 2,100 psi to about 4,300 psi, about 2,100 psi to about 5,400 psi, about 2,100 psi to about 5,600 psi, about 2,100 psi to about 4,800 psi, about 2,100 psi to about 8,000 psi, about 1,100 psi to about 7,500 psi, about 4,100 psi to about 10,000 psi, about 5,100 psi to about 11,500 psi, about 6,200 psi to about 7.300 psi. about 5,200 psi to about 9,400 psi, about6.200 psi to about 9,600 psi, about 5,200 psi to about 11,800 psi, about 1,200 psi to about 10,000 psi, about 2,000 psi to about 10,000 psi, about 3,000 psi to about 10,000 psi, about 4,000 psi to about 10,000 psi, about 5,000 psi to about 10,000 psi, about 6,000 psi to about 10,000 psi, about 7,000 psi to about 10,000 psi, about 8,000 psi to about 10,000 psi, about 9,000 psi to about 10,000 psi, or about 10,200 psi to about 12,000 psi. In some embodiments, a bioconcrete construction material has a compressive strength of about 1,000 psi, about 2,000 psi, about 3,000 psi, about 4.000 psi. about 5,000 psi, about 6,000 psi, about 7,000 psi, about 8,000 psi, aboutDocket No.: BMI-1016PCT9,000 psi, about 10,000 psi, about 11,000 psi, or about 12,000 psi. In some embodiments, a bioconcrete construction material has a compressive strength of at least 900 psi, 1,000 psi, 2,000 psi, 3,000 psi, 4.000 psi. 5,00 psi, 6,000 psi, 7.000 psi, 8,000 psi. 9,000 psi, 10,000 psi. 11.000 psi, or 12,000 psi.

[0074] In some embodiments, any construction material described herein (e.g., made with any of the methods or systems described herein) has a flexural strength of from 1 to 20 MPa, (e.g., from 1 to 5 MPa, from 2 to 6 MPa, from 2 to 12 MPa, from 3 to 9 MPa, from 4 to 8 MPa, from 3 to 10 MPa, from 5 to 15 Mpa, from 3 to 11 MPa, from 4 to 12 MPa, from 5 to 10 MPa, from 8 to 15 MPa, from 9 to 18 MPa, from 10 to 20 MPa, from 5 to 20 MPa, from 12 to 20 MPa, or from 15 to 20 MPa. In some embodiments, any construction material described herein (e.g., made with any of the methods or systems described herein) has a flexural strength of at least 1 MPa, at least 2 MPa, at least 3 MPa. at least 4 MPa, 5 MPa, at least 6 MPa, at least 7 MPa, at least 8 MPa. at least 9 MPa, at least 10 MPa. at least 11 MPa, at least 12 MPa, at least 13 MPa, at least 14 MPa, 15 MPa, at least 16 MPa, at least 17 MPa, at least 18 MPa, at least 19 MPa, or at least 20 MPa. In some embodiments, any construction material described herein (e g., made with any of the methods or systems described herein) has a flexural strength of about 1 MPa, about 2 MPa, about 3 MPa, about 4 MPa, 5 MPa, about 6 MPa, about 7 MPa, about 8 MPa, about 9 MPa, about 10 MPa, about 11 MPa, about 12 MPa, about 13 MPa, about 14 MPa, 15 MPa, about 16 MPa, about 17 MPa, about 18 MPa, about 19 MPa, or about 20 MPa.

[0075] In some embodiments, any construction material described herein remains undamaged after 5 cycles of an EN 14617-5 freeze / thaw test. In some embodiments, any construction material described herein remains undamaged after 10 cycles of an EN 14617-5 freeze / thaw test. In some embodiments, any construction material described herein remains undamaged after 25 cycles of an EN 14617-5 freeze / thaw test. In some embodiments, any construction material described herein remains undamaged after 30 cycles of an EN 14617-5 freeze / thaw test.

[0076] In some embodiments, any construction material described herein (e.g., made with any of the methods or systems described herein) has a finished density of from about 2 g / cc to about 3 g / cc, for example, 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, from about 2.6 g / cc to about 2.7 g / cc. from about 2.8 g / cc to about 2.9 g / cc. from about 2.9 g / cc to about 3.0 g / cc, from about 3.0 g / cc to about 3.1 g / cc, from about 3.1 g / cc to about 3.2 g / cc. In some embodiments, the average finishedDocket No.: BMI-1016PCT density is from about 2.0 g / cc to about 2.1 g / cc. In some embodiments, the average finished density is from about 2.1 g / cc to about 2.3 g / cc. In some embodiments, the average finished density is from about 2.2 g / cc to about 2.4 g / cc. In some embodiments, tire average finished density is from about 2.0 g / cc to about 2.5 g / cc. In some embodiments, the average finished density is from about 2.5 g / cc to about 3 g / cc. In some embodiments, the average finished density is about 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, or 3.3 g / cc. In some embodiments, the average finished density is greater than 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, or 3.3 g / cc.

[0077] Methods of Producing a Construction Material

[0078] Provided in various embodiments herein is a method of producing any suitable construction materials described herein.

[0079] In some embodiments, any method provided herein comprises adding a plurality of aggregate particles to a framework, thereby forming a framed plurality of aggregate particles; substantially purging air from void space between the framed plurality of aggregate particles; flowing a first fluid comprising cementation reagents through the framed plurality’ of aggregate particles; and reacting the cementation reagents with a biological organism and / or an enzyme comprised within the fluid or within the framed plurality of aggregate particles for a sufficient time to consolidate the framed plurality of aggregate particles, thereby forming the construction material.

[0080] In some embodiments, any method provided herein comprises compacting a plurality of aggregate particles in a framework to reduce a volume of void-space between adjacent particles of the plurality of aggregate particles; flowing a first fluid comprising cementation reagents through the void space of the plurality of aggregate particles; and reacting the cementation reagents with a biological organism and / or an enzyme comprised within tire fluid or within tire framed plurality of aggregate particles for a sufficient time to consolidate tire framed plurality of aggregate particles, thereby forming the construction material.

[0081] In some embodiments, any method provided herein comprises adding a plurality’ of any suitable aggregate particles described herein to any suitable framework described herein. In some embodiments, adding a plurality of aggregate particles to a framework result in forming a framed plurality of aggregate particles.

[0082] In some embodiments, any aggregate used in any method, reusable framework, or system provided herein comprises any suitable aggregate. In some embodiments, any suitable aggregate comprises a plurality of aggregate particles. In specific embodiments, a plurality ofDocket No.: BMI-1016PCT aggregate particles comprises sand, gravel, a combination of sand and gravel, or any suitable material. In some embodiments, a plurality of aggregate particles comprises sand. In some embodiments, a plurality of aggregate particles comprises gravel. In some embodiments, a plurality of aggregate particles comprises a blend of sand and gravel. In some embodiments, a plurality of aggregate particles consists essentially of a blend of sand and gravel.

[0083] In more specific embodiments, a blend of sand and gravel comprises any percentages of volume of sand and gravel suitable for producing a construction material.

[0084] In some embodiments, a blend of sand and gravel comprises 1-99% sand and 1-99% gravel by volume. In some embodiment, a blend of sand and gravel comprises 55-75% sand and 25-45% gravel by volume. In some embodiments, a blend of sand and gravel comprises 66% sand and 34% gravel. In some embodiments, a blend of sand and gravel comprises 1% sand and 90% gravel. In some embodiments, a blend of sand and gravel comprises 90% sand and 1% gravel. In some embodiments, a blend of sand and gravel comprises 20% sand and 80% gravel. In some embodiments, a blend of sand and gravel comprises 80% sand and 20% gravel. In some embodiments, a blend of sand and gravel comprises 60% sand and 40% gravel. In some embodiments, a blend of sand and gravel comprises 40% sand and 60% gravel. In some embodiments, a blend of sand and gravel comprises 50% sand and 50% gravel.

[0085] In some embodiments, an average particle size of the sand is smaller than an average particle size of the gravel. In some embodiments, an average particle size of the sand is at least a factor of 10 (e g., at least a factor of 20, 50, or 100) smaller than an average particle size of the gravel. In some embodiments, an average particle size of the sand is at least a factor of 20 smaller than an average particle size of the gravel. In some embodiments, an average particle size of the sand is at least a factor of 50 smaller than an average particle size of the gravel. In some embodiments, an average particle size of tire sand is at least a factor of 100 smaller than an average particle size of the gravel. In some embodiments, an average particle size of the sand is at least a factor of 200 smaller than an average particle size of the gravel. In some embodiments, an average particle size of the sand is at least a factor of 500 smaller than an average particle size of the gravel.

[0086] In some embodiments, a plurality of aggregate particles can be in any suitable state that can be used for generating a construction material described herein. In some embodiments, a plurality7of aggregate particles can be wet. In some embodiments, a plurality7of aggregate particles can be solvated. In some embodiments, a plurality7of aggregate particles can be solid. In some embodiments, a plurality of aggregate particles can be slurry.Docket No.: BMI-1016PCT

[0087] In some embodiments, a plurality of aggregate particles can be mixed with any suitable cementation reagents provided herein prior to being added to the framework.

[0088] In some cases, the concentration of cells of a biological organism added to tire aggregate mix is grown to at least a particular concentration or to at least a particular number of cells prior to being added to the aggregate mix. In some embodiments, the concentration of cells of the biological organism in a solution added to the aggregate mix is about 10,000 CFU / mL to about 1,000,000,000,000 CFU / mL, or is about 10,000 CFU / mL to about 100,000 CFU / mL, or is between 10,000 CFU / mL and 100,000,000 CFU / mL, or is between 1,000,000 CFU / mL and 10,000,000 CFU / mL, , or is between 1,000,000 CFU / mL and 100,000,000 CFU / mL, or is between 1,000,000 CFU / mL and 10,000,000 CFU / mL, or is between 1,000,000 CFU / mL and 100,000,000 CFU / mL, or is between 1.000,000 CFU / mL and 1,000,000,000 CFU / mL or is between 1,000,000 CFU / mL and 10,000.000,000 CFU / mL, or is between 10.000,000 CFU / mL and 1,000.000,000 CFU / mL. or is betw een 100,000,000 CFU / mL and 1,000,000.000 CFU / mL. A concentration of cells of organisms in the aggregate prior to feeding cementation reagents may be betw een about 1 x 102and 1 x 1012CFU per gram of aggregate blend mass, e.g., betw een 1 x 103and 1 x IO10CFU per gram, e.g., between 1 x 105and 5 x 109CFU per gram, e.g., between 1 x 107and 5 x 109CFU per gram, e.g., between 1 x 106and 2 x 109CFU per gram, e.g., between 5 x 105and 2 x 109CFU per gram, e.g., between 1 x 108and 1 x 1012CFU per gram, e.g., between 1 x 109and 1 x 1011CFU per gram, e g., between 1 x 1010and 1 x 1012CFU per gram).

[0089] In further embodiments, any method provided herein comprises adding any suitable reinforcing material (e.g., rebar, fiberglass rebar, or fiberglass strands) to the framework. In some embodiments, a reinforcing material comprises a rebar. In some embodiments, a reinforcing material comprises a fiberglass rebar. In some embodiments, a reinforcing material comprises a fiberglass strand. In some embodiments, a reinforcing material is added prior to add the plurality of aggregate particles described herein. In some embodiments, a reinforcing material is added concurrently with the adding the plurality of aggregate particles.

[0090] In some embodiments, any method provided herein comprises settling the added plurality of aggregate particles into a mold cavity of the framework in any suitable manner. In some embodiments, a settling can be performed by any suitable maimer to reduce tire volume of void space within the mold. In some embodiments, a settling can be perfonned by using any suitable mechanical force. In some embodiments, a settling can be pressing the plurality’ of aggregate particles. In some embodiments, a settling can be applying vibration to the pluralityDocket No.: BMI-1016PCT of aggregate particles. In some embodiments, a settling can be pressing and applying vibration to the plurality of aggregate particles.

[0091] In some embodiments, a settling can be performed while the plurality of aggregate particles is dry. In some embodiments, a settling can be performed while the plurality of aggregate particles is wet. In further embodiments, the settling is at least partially performed by applying a pressurized solvent (e.g., water) to the particles at any suitable pressure configured to increase the packing density of the particles.

[0092] In some embodiments, a pressure of any of the fluidic flows applied to the framed plurality of particles is any suitable pressure. In some embodiments, the pressure is at least about 1 psi (e g., at least about 5, 10, 20, 50, or 100 psi). In some embodiments, the pressure is at least about 5 psi. In some embodiments, the pressure is at least about 10 psi. In some embodiments, the pressure is at least about 20 psi. In some embodiments, the pressure is at least about 50 psi. In some embodiments, tire pressure is at least about 100 psi. In some embodiments, the pressure is at least about 250 psi.

[0093] In some embodiments, any cementation reagent described herein comprises any suitable cementation reagent for producing a construction material. In some embodiments, a cementation reagent comprises a biological organism (or spores thereof), an enzyme, urea (and / or derivatives thereof), a calcium salt (e.g.. CaCb). nutrients, or combinations of two or more thereof. In some embodiments, a cementation reagent comprises any suitable biological organism (or spores thereof). In specific embodiments, the biological organism is a ureaseproducing organism (or spores thereof). The urease-producing microorganism may be from the domains of archaea (e.g., haloarchaea), bacteria, or eukarya (e.g., fungi (e.g., yeasts (e.g., of tire genus saccharomyces) or filamentous fungi (e.g., of the genus Aspergillus)), and some algae (e.g., Thraustochytrids)). Urease-producing bacteria include organisms in tire phyla Pseudmonadota (e.g., of the classes Alphaproteobacteria, Betaprobacteria. Gammaprobacteria (e.g., organisms of the order Enterobacterales, e.g., organisms of the family Enterobacteriaceae, e g., of the genus Proteus, (e g., species related to Proteus mirabilis and Proteus vulgaris), or, e.g., organisms of the order Alteromonadales, e.g., of the family Shewanellaceae (e.g., of the genus Shewanella, e.g., species such as Shewanella putrefaciens, Shewanella oneidensis, Shewanella sediminis, etc.)), Deltaproteobacteria), Firmicutes, Campylobacterota (e g., of tire class Campylobacteria, e.g., of the order, campylobacterales, e.g., of the family Helicobacteraceae, e.g., of the genus Helicobacter, e.g., organisms related to Helicobacter pylori), Myxococcota (e.g., of the class Myxococcia, e.g.. of the order Myxococcales. e.g., of the family Myxococcaceae, e.g., a species such as Myxococcus Xanthus) or Actinobacteria (e.g.,Docket No.: BMI-1016PCT are considered. Urease producing Firmicutes include organisms include, e.g., organisms of tire family Bacillaceae (e.g., Alkalibacillus, Alkalicoccus, Alkalilialobacillus, Bacillus, Halalkalibacillus, Halobacillus, Halolactibacillus, Lysinibacillus, Lederbergia (e.g., Lederbergia lenta), Natribacillus, Natronobacillus, Priestia, Pseudobacillus, Pseudogracilibacillus, Pseudoneobacillus, Psychrobacillus, Thermalkalibacillus; for example, species such as Lysinibacillus sphaericus, Bacillus sphaericus, Bacillus subtilis, Bacillus megaterium, etc.) or, e.g., of the family Caryophanaceae (e.g., of the genus Sporosarcina (e.g., species such as Sporosarcina pasteurii or Sporosarcina ureae), e.g., of the genus Bhargavaea (e.g., Bhargavaea beijingensis)), or, e.g., of tire family Paenibacillaceae (e.g., of the genus Paenibacillus). In more specific embodiments, the urease-producing organism is Sporosarcina pasteurii. In some embodiments, a cementation reagent comprises any suitable enzyme. In some embodiments, a cementation reagent comprises urea (and / or derivatives thereof). In specific embodiments, wherein the enzyme is urease. In some embodiments, a cementation reagent comprises any suitable enzyme. In some embodiments, a cementation reagent comprises a calcium salt (e.g., CaCL). In some embodiments, a cementation reagent comprises nutrients which promote activation or expression of enzymes. In some embodiments, a cementation reagent comprises nutrients for feeding a bacteria. In some embodiments, cementation reagents include an acid-producing enzyme or a acid-producing microorganism (e.g., one that produces one or more acid-producing enzymes). Acid producing microorganisms may be from the domains of archaea (e.g., haloarchaea), bacteria, or eukarya (e.g., fungi (e.g., yeasts (e.g., of the genus saccharomyces) or filamentous fungi (e.g., of the genus Aspergillus)), and some algae (e.g., Thraustochytrids)). The acid-producing microorganism may be selected from the group consisting of: Acctobactcr (e.g., Acetobacter aceti), Variovorax, Klebsiella, Pseudomonas, Bacillus, Exiguobacterium, Microbacterium, Curtobacterium, Rathayibacter. Streptomyces, Raoultella, B. pumilus, B. safanensis, B. simplex, B. licheniformis, Lysinibacillus sphaericus and combinations thereof. In some embodiments, cementation reagents include one or more carbonic anhydrase enzyme(s), or one or more microorganisms which express carbonic anhydrase enzyme(s). In some embodiments, the carbonic anhydrase-producing microorganisms may be the same organism as the urease-producing microorganism or the acidproducing microorganism. In some embodiments the carbonic anhydrase -producing microorganism is a different microorganism to the urease-producing microorganism. In some embodiments, a feed solution (e.g., a liquid solution comprising dissolved or dispersed cementation reagents) or aggregate mix of a system or method described herein may include carbonic anhydrase enzyme (or a carbonic anhydrase-producing microorganism, e.g., from the domains of archaea, bacteria (e.g., thermophilic bacteria), or eukarya (e.g., fungi (e.g., yeastsDocket No.: BMI-1016PCT(e.g., of the genus saccharomyces) or filamentous fungi (e.g., of the genus Aspergillus)), and some algae) and may be further fed gaseous carbon dioxide, e.g., captured carbon dioxide, e.g., directly into the feed solution or into the framework. In some embodiments, cementation reagents in the aggregate include enzymes or organisms and cementation reagents in fluids provided to the aggregate (e.g., feed solutions) comprise a calcium ion source (e.g., calcium chloride). In some embodiments, the cementation reagents in the aggregate include enzymes or organisms and cementation reagents in fluids provided to the aggregate (e.g., feed solutions) comprise a calcium ion source (e.g., calcium chloride) and urea. In some embodiments, the cementation reagents in tire aggregate include enzymes or organisms and urea, and cementation reagents in fluids provided to the aggregate (e.g., feed solutions) comprise a calcium ion source (e.g., calcium chloride) and urea.

[0094] In some embodiments, one or more fluids provided to the aggregate in the framework include microorganisms or enzymes. In some embodiments, one or more fluids provided to the aggregate in the framework do not include microorganisms or enzymes (or include only trace amounts e.g., less than 0. 1 g per liter of enzyme or microorganism, e.g., less than 1000 CFU per liter of microorganisms, e.g., less than 100 CFU per liter of microorganisms, e.g., less than 10 CFU per liter of microorganisms, e.g., less than 1 CFU per liter of microorganisms, e.g., has a specific urease activity or specific carbonic anhydrase activity’ that is not statistically different from a source of water used in the process).

[0095] In some embodiments, the cementation reagents comprised in the first fluid comprise any biological organism (e.g.. a microorganism) (or spores thereof) and / or any enzyme described herein. In some embodiments, the cementation reagents comprised in the first fluid comprise any biological organism (or spores thereof) and any enzyme described herein. In some embodiments, the cementation reagents comprised in the first fluid comprise any biological organism (or spores thereof) or any enzyme described herein. In some embodiments, the cementation reagents comprised in the first fluid comprise any biological organism (or spores thereof). In some embodiments, the cementation reagents comprised in the first fluid comprise any enzyme described herein. In some embodiments, the cementation reagents comprised in the first fluid comprise any suitable nutrients. In some embodiments, the cementation reagents comprised in the first fluid comprise any suitable nutrients that promote activity of the biological organism and / or the enzyme. In alternative embodiments, the cementation reagents comprised in the first fluid do not comprise nutrients that promote activity of the biological organism and / or the enzyme.Docket No.: BMI-1016PCT

[0096] In some embodiments, the cementation reagents comprised in the second fluid comprise nutrients that promote activity of the biological organism and / or the enzyme.

[0097] In some embodiments, any method provided herein comprises substantially purging air from void space between the framed plurality of aggregate particles prior to the reacting in any suitable manner described herein such as using pressure or mechanical force. In some embodiments, purging air can be performed in the same manner as the settling as described herein.

[0098] In some embodiments, any method provided herein comprises compacting a plurality of aggregate particles in a framework in any suitable manner. In some embodiments, any method provided herein comprises compacting a plurality of aggregate particles in a framework to reduce a volume of void-space between adjacent particles of the plurality of aggregate particles in any suitable manner described herein such as using pressure or mechanical force. In some embodiments, compacting can be performed in the same manner as the settling as described herein.

[0099] In some embodiments, any method provided herein comprises reacting tire cementation reagents with a biological organism and / or an enzyme comprised within the fluid or within the framed plurality of aggregate particles described herein. In some embodiments, a method comprises reacting the cementation reagents with a biological organism and / or an enzyme comprised within the fluid or within the framed plurality of aggregate particles for a sufficient time to consolidate tire framed plurality of aggregate particles. In some embodiments, a method comprises reacting the cementation reagents with a biological organism and / or an enzyme comprised within the fluid or within the framed plurality of aggregate particles for a sufficient time to consolidate tire framed plurality of aggregate particles, thereby forming the construction material. In some embodiments, the reacting binds adjacent particles of the plurality of particles together with calcium carbonate bridges, thereby forming the construction material.

[0100] Reusable Framework for Producing a Precast Bioconcrete Construction Material

[0101] Provided in some embodiments herein is a reusable framework for producing a precast bioconcrete construction material as described herein.

[0102] In some embodiments, a reusable framework for producing a precast bioconcrete construction material comprises: a plurality’ of panels configured to: (i) temporarily fasten together to form a fluidically coupled system during curing of a precast bioconcrete constructionDocket No.: BMI-1016PCT material, and (ii) unfasten to allow release of the precast construction material from a mold cavity formed when the plurality of panels are fastened together; a cementation reagent inlet; a cementation reagent outlet; wherein a volume of tire mold cavity formed when the panels are fastened together is at least 50 L (e.g., at least 100L, or at least 1000L), the cementation reagent inlet is located on at least one of the plurality of panels and is configured to be fluidically coupled to the mold cavity when the plurality of panels are temporarily fastened, the cementation reagent outlet is located on at least one of the plurality' of panels and is configured to be fluidically coupled to the mold cavity when the plurality of panels are temporarily fastened.

[0103] In some embodiments, a reusable framework provided herein comprises any suitable panels. In some embodiments, a reusable framework comprises a plurality of panels. In some embodiments, the plurality’ of panels is configured to temporarily fasten together to form a fluidically coupled system as described herein. In specific embodiments, the plurality of panels is configured to temporarily fasten together to form a fluidically coupled system during curing of a construction material as described herein. In specific embodiments, the plurality of panels is configured to temporarily fasten together to form a fluidically coupled system during curing of a precast bioconcrete construction material. In some embodiments, the plurality of panels is configured to unfasten. In specific embodiments, unfastening allows release of any construction material from a mold cavity formed when tire plurality of panels is fastened together. In some embodiments, the plurality of panels is configured to: (i) temporarily fasten together to form a fluidically coupled system during curing of a precast bioconcrete construction material, and (ii) unfasten to allow release of the precast construction material from a mold cavity formed when the plurality of panels is fastened together.

[0104] In some embodiments, a plurality of panels described herein includes at least one panel imprinted with a pattern configured to alter the aesthetic appearance of one or more surfaces of any suitable construction material. In some embodiments, a plurality of panels described herein includes at least one panel imprinted with a pattern configured to alter the aesthetic appearance of one or more surfaces of the precast construction material. In some embodiments, a plurality’ of panels described herein include a void (e.g., a convexity, e.g., a cavity, e.g., a curved void, e.g., a groove, e.g., a hollow) on the interior face when assembled into a framework. In some embodiments, a plurality of panels described herein include a void (e.g., a convexity', e.g., a cavity, e.g., a curved void, e.g., a groove, e.g., a hollow) on the exterior face when assembled into a framework. In some embodiments, an outlet is disposed in an apex of the void, an upper portion of the void, or a portion of the void that is furthest from an inlet in the framework.Docket No.: BMI-1016PCT

[0105] In some embodiments, a plurality of panels described herein is configured to be modular, allowing for multiple types or quantities of any suitable construction materials to be manufactured using the same reusable framework. In some embodiments, a plurality of panels is configured to be modular, allowing for multiple types or quantities of precast bioconcrete materials to be manufactured using the same reusable framework. In some embodiments, the plurality of panels includes an inlet panel and an outlet panel which together assemble with one or more additional panels such that the inlet panel and outlet panel are at opposite ends of a longest dimension of the assembled framework.

[0106] In some embodiments, a precast bioconcrete material produced by any framework provided herein comprises a plurality of pavers, a modular wall panel, a free-standing construction (such as an L-wall, a jersey barrier, F-shape barrier, constant slope barrier, Ontario tall wall, concrete step barrier, etc.). In some embodiments, a precast bioconcrete material comprises a paver. In some embodiments, a precast bioconcrete material comprises a plurality of pavers. In some embodiments, a precast bioconcrete material comprises a free-standing construction (such as an L-wall, T-wall, a jersey barrier, F-shape barrier, constant slope barrier, Ontario tall wall, concrete step barrier, etc.). In some embodiments, a precast bioconcrete material comprises a wall panel. In some embodiments, a precast bioconcrete material comprises a modular wall panel. In some embodiments, a precast bioconcrete material comprises jersey barrier. In some embodiments, a precast bioconcrete material comprises a pillar.

[0107] In some embodiments, a reusable framework provided herein comprises any suitable cementation reagent inlet. In some embodiments, a reusable framework provided herein comprises any suitable cementation reagent outlet. In some embodiments, a reusable framework provided herein comprises any suitable cementation reagent inlet and outlet.

[0108] In some embodiments, the cementation reagent inlet is located on at least one of the plurality of panels as described herein and is configured to be fluidically coupled to the mold cavity when the plurality of panels is temporarily fastened as described herein. In some embodiments, the cementation reagent inlet is configured to be located on a lower panel than the cementation reagent outlet when the plurality of panels is temporarily fastened. In some embodiments, tire cementation reagent inlet is configured to allow for pressurization of a fluid within the mold cavity of the reusable framework.

[0109] In some embodiments, tire cementation reagent outlet is located on at least one of the plurality of panels as described herein and is configured to be fluidically coupled to tire mold cavity when the plurality of panels is temporarily fastened as described herein. In someDocket No.: BMI-1016PCT embodiments, the cementation reagent outlet is configured to allow for pressurization of a fluid within the mold cavity of the reusable framework.

[0110] In some embodiments, the cementation reagent inlet and / or the cementation reagent outlets are configured to allow for pressurization of a fluid within tire mold cavity of tire reusable framework. In some embodiments, the cementation reagent inlet and the cementation reagent outlets are configured to allow for pressurization of a fluid within the mold cavity of the reusable framework. In some embodiments, the cementation reagent inlet or the cementation reagent outlets are configured to allow for pressurization of a fluid within the mold cavity of the reusable framework.

[0111] In some embodiments, a reusable framework provided herein comprises any suitable air vents. In some embodiments, an air vent is configured to allow a purging of air from the mold cavity. In some embodiments, a reusable framework provided herein comprises any suitable numbers of air vents. In some embodiments, a reusable framework provided herein comprises one air vent. In some embodiments, a reusable framework provided herein comprises more than one air vent. In some embodiments, the air vents include stop valves that permit the passage of air but prevent the passage of liquid (e.g., water), e.g., a valve including a buoyant element.

[0112] In some embodiments, in a reusable framework provided herein, a volume of the mold cavity formed when the panels are fastened together is at least 50 L (e.g., at least 100L, or at least WOOL). In some embodiments, a volume of the mold cavity formed when the panels are fastened together is at least 100 L. In some embodiments, a volume of the mold cavity formed when the panels are fastened together is at least 500 L. In some embodiments, a volume of the mold cavity formed when the panels are fastened together is at least 1000 L. In some embodiments, a volume of the mold cavity formed when the panels are fastened together is at least 2000 L.

[0113] System for Producing a Precast Bioconcrete Construction Material

[0114] Provided in some embodiments herein is a system for producing a precast bioconcrete construction material as described herein.

[0115] In some embodiments, a system provided herein comprises any reusable framework described herein, any suitable fluidic manifold and any suitable pump. In some embodiments, a system provided herein comprises any reusable framework described herein. In some embodiments, a system provided herein comprises any suitable fluidic manifold. In some embodiments, a system provided herein comprises any suitable pump. In some embodiments, aDocket No.: BMI-1016PCT pump is fluidically coupled to a fluidic manifold, the cementation reagent inlet and / or the cementation reagent outlet of the reusable framework. In some embodiments, a pump is fluidically coupled to a fluidic manifold. In some embodiments, a pump is fluidically coupled to a cementation reagent inlet described herein. In some embodiments, a pump is fluidically coupled to a cementation reagent outlet described herein. In some embodiments, a pump is fluidically coupled to a fluidic manifold, a cementation reagent inlet or a cementation reagent outlet of the reusable framework. In some embodiments, a pump is fluidically coupled to a fluidic manifold, a cementation reagent inlet and a cementation reagent outlet of the reusable framework.

[0116] In further embodiments, a system provided herein further comprises any suitable recirculation reservoir configured to recirculate any fluid described herein through any reusable framework described herein.

[0117] In further embodiments, a system provided herein further comprises any suitable reagent reservoir configured to provide fresh cementation reagents described herein to a recirculation reservoir described herein, to the mold cavity of a reusable framework described herein, or both. In some embodiments, a system provided herein comprises any suitable reagent reservoir configured to provide fresh cementation reagents described herein to a recirculation reservoir described herein. In some embodiments, a system provided herein comprises any suitable reagent reservoir configured to provide fresh cementation reagents described herein to the mold cavity of a reusable framework described herein. In some embodiments, a system provided herein comprises any suitable reagent reservoir configured to provide fresh cementation reagents described herein to a recirculation reservoir described herein or the mold cavity of a reusable framework described herein. In some embodiments, a system provided herein comprises any suitable reagent reservoir configured to provide fresh cementation reagents described herein to a recirculation reservoir described herein and the mold cavity of a reusable framework described herein.

[0118] In further embodiments, a system provided herein further comprises any suitable reservoirs. In some embodiments, a reservoir is configured to accumulate waste fluid and / or fluid which has been depleted of cementation reagents. In some embodiments, a reservoir is configured to accumulate waste fluid and fluid which has been depleted of cementation reagents. In some embodiments, a reservoir is configured to accumulate waste fluid or fluid which has been depleted of cementation reagents. In some embodiments, a reservoir is configured to accumulate waste fluid. In some embodiments, a reservoir is configured to accumulate fluid which has been depleted of cementation reagents as described herein.Docket No.: BMI-1016PCT

[0119] In some embodiments, a system provided herein to perform any method provided herein.EXAMPLES

[0120] The application may be better understood by reference to the following non-limiting examples, which are provided as exemplary embodiments of the application. The following examples are presented in order to more fully illustrate embodiments and should in no way be construed, however, as limiting tire broad scope of the application.

[0121] Example 1 - Pavers Manufactured Using Dry Aggregate Mix

[0122] Process

[0123] A 7-unit paver framework was used as a mold to pack an aggregate into each paver cavity' (FIG. 1A). The activated Danish aggregate S66T34 was used as the aggregate blend. The paver framework contained aggregate on all six sides (FIG. IB). 60 liters of tire dry aggregate were used to yielding 7 pavers at 8.39 liters each. The 7 pavers include paver 102. Immediately after compacting the dry aggregate into the mold, the top section was securely attached, and the entire mold was elevated. There was no cure time allowing the aggregate to dry before feeding.

[0124] The feeding scheme was demonstrated in FIG. 2. Urea, CaCh and nutrients were used to feed each paver. Specifically, tire feeding process employed a single 1 OO-liter container equipped with a sump pump (e.g., a recirculating pump) positioned directly beneath the mold or paver framework 104. Utilizing flexible tubing, the sump pump connected to the bottom section of the mold's plenum, while another flexible tube was affixed to the top plenum, facilitating tire recirculation of fluid back into the 1 OO-liter container. A bath containing 50 liters of CaCL / Urca feed solution was introduced into the 1 OO-liter container. The fluid was then propelled through the mold from tire bottom plenum to tire top plenum using the sump pump. This recirculation process continued for a duration of 3 hours and 50 minutes, allowing for 10 minutes to drain the mold and replace the bath with a fresh 50-liter solution.

[0125] The original intention was to carry out a total of 12 such baths. However, the sump pump malfunctioned after the ninth bath, a problem that went unnoticed for several baths due to a lack of monitoring. This ultimately resulted in the experiment being cut short. Despite all 12 baths being prepared and positioned in tire 1 OO-liter container, it is suspected that the last three baths never entered the mold. In total, 450 liters of fluid (600 liters accounting for all 12 baths) were used. The mold was disassembled immediately after the twelfth bath, without undergoing any rinsing or additional curing time. Unfortunately, during the disassembly process, several of the pavers fractured, likely due to the absence of painting of the steel moldDocket No.: BMI-1016PCT and the fact that the aggregate had become cemented to the steel plates. Within a week, tire pavers were cut into different samples for testing purposes.

[0126] Performance Tests

[0127] The positions of tire samples that were taken were illustrated in FIG. 3A. Solid outline is equivalent to a 16” (400mm) square paver. Each dashed square inside the paver is equivalent to a 2” (50 min) cube with the full solid square being 400mm x 400 mm x 50 mm paver.

[0128] The compressive strength and EOR density were tested in the dashed square samples on the side and tire bottom (FIG. 3A), and the results are shown in FIG. 3B. The compressive strength of the samples was from 2,200 PSI to 9.200 PSI. The EOR density of the samples was from 1.89 g / cc to 2.28 g / cc.

[0129] The flexural strength was tested in FW38 and FW45 (FIG. 3A), and the results are shown in FIG. 3C. The flexural tests were completed. The average flexural strength was 8.9 MPa, which would designate the highest level of marking for flagstone pavers.

[0130] Initial absorption tests were also conducted and indicated 3.85% absorption. In addition, global warming potential (GWP) was from 15.0 kg CO2eq / m2 to 6.0 kg CO2eq / m2at 2cm equivalence. These results demonstrate that microbially-induced calcite precipitation (MICP) can produce pavers meeting the specified standards while maintaining a low GWP.

[0131] Example 2 - Process for Manufacturing Small Format Precast Articles Using Dry Aggregate Mix

[0132] 100 sq. ft. of BS EN 1339:2003 24” x 24” x 3” flag pavers, or any other bioconcrete article or articles having approximately the same total volume as tire 100 sq. ft. of such pavers can be produced by a system using a framework, a cell culture, and a feedstock bath.

[0133] Examples of a framework sized to be sealed between the top and bottom plenums of a system, e.g., between the top and bottom plenums for a panel mold with a rectangular external footprint (e.g., panel mold) are illustrated in FIG. 4A. FIG. 4B illustrates an exploded view of a system for producing pavers. Multiple pavers (e.g., seven pavers) may be produced by the system simultaneously.

[0134] A cell culture can be prepared according to tire following operating procedure. A container (e g., a drum or tote), pumps, and associated hoses are thoroughly cleaned with alconox and rinsed with clean water prior to inoculation. Wet test system with clean water at full run volume is also conducted to verify aeration and mixing typical of large volume cultureDocket No.: BMI-1016PCT growth. 750 L of clean tap water are added to a tote with a target final temperature of 33° C. System recirculation pumps are turned on to begin mixing. All dry components of cell culture medium except the cells on their solid support are added and mixed via system recirculation. Media temperature is checked after dry materials are thoroughly mixed. A temperature drop of approximately 1° C is expected due to urea dissolution. After verifying the media temperature is between 31°-33° C, the solid-supported cells are added to the recirculating tote. Culture growth is estimated to take 20-24 hours. Culture temperature should be maintained within the range of 30° C - 35° C during growth. After 20-24 hours of growth, the cell population for adequate cell densify (e.g., by optical density) is checked. The aggregate in the framework is inoculated by recirculating the culture through the aggregate starting at the bottom plenum.

[0135] After inoculation, the system is switched over to provide feedstock to the aggregate. The feedstock bath is prepared according to the following protocol. 250 L water is added to the mixing tote at approximately 30° C. Urea (5-10 kg) and nutrients are added slowly while mixing in the tote. CaCF (10-20 kg) are added in the mixing tote slowly to maintain the temperature within the correct range. Water is added to reach 400 L in the mixing tote with target temperature of 30° C.

[0136] The panel mold to produce the 100 sq. ft. of pavers described above is expected to take a total of (15) baths per run, with feedstock bath changes on a 4-hour schedule.

[0137] Example 3 - Process for Manufacturing Large Format Precast Articles Using Wet Aggregate Mix

[0138] L-WALL BARRIER

[0139] An L-wall barrier was produced according to embodiments of the system and methods of the disclosure utilizing pre-inoculated wet aggregate mix (S66T34) Skygge Blend.

[0140] Mold Preparation

[0141] An L-shaped framework (L-shaped mold 502) (FIG. 5A) was acid washed and cleaned to ensure the mold cavity surfaces are smooth and clear of debris from previous runs. Fabric was added to the grating on the top and bottom plenum to act as a filter to prevent aggregate washout. Foam gaskets and silicone were added to the mold flanges to ensure a watertight seal when clamped. The mold was then bolted together using an impact drill leaving off the top plenum for aggregate packing. All internal metal sides were then oiled with a non-stick coating.

[0142] PackingDocket No.: BMI-1016PCT

[0143] The mold was evenly filled with inoculated aggregate without exceeding a depth which allowed for sufficient compaction. The packing tool was applied to the mold to apply pressure until the aggregate was sufficiently compacted. After removing the packing tool, the surface of the compacted aggregate was scoured to prevent any visible seams in the layers of the compacted aggregate. The process was repeated until the mold was filled. The gasket and filter fabric were placed on top of the compacted aggregate before placing the top plenum.

[0144] Feeding

[0145] A Pre-Nutrix solution was diluted with water to a 10: 1 ratio. The solids in the solution were allowed to settle and the dilute liquid collected to be used in feed preparation. Bath preparation started with portioning out the calcium chloride and urea. Initially, the bath tank was filled with 100 L of water at or below room temperature. All feed components were added to the bath tank and mixed until dissolved. Water was then added until 150 L was reached using appropriately heated water to achieve the target bath temperature of 35°C. The feed was added to the aggregate by pumping the bath solution from the bath tank into the bottom plenum of the mold and discharged from the mold's top plenum back into the bath tank, allowing the feed to circulate through the mold. The feed circulation through the mold was repeated until the first bath change. The feedstock was changed. The feeding process was repeated until the process was deemed complete.

[0146] Demolding

[0147] Once the feeding was complete, the bath tank and mold were drained. The bolts from the mold were removed and the mold walls carefully separated from the cemented structure. The L-wall barrier 504 is shown in FIG. 5B.

[0148] Similarly, other precast construction materials, such as a modular wall panel 602 (FIG. 6), a jersey barrier 702 (FIG. 7A), or a pillar (FIG. 8A), can also be produced using the same process using either a dry or wet mix with different molds. A 1.98 m3 wall panel produced was tested in a few uniform regions and had a compressive strength between 2,459 and 4,715 PSI. A 0.6 m3 jersey barrier produced was tested in a few uniform regions and had a compressive strength between 988 and 2,451PSI.

[0149] Fiberglass rebar elements can be placed into the mold to increase unit tensile strength, such as rebar element 712 in FIG. 7B. Examples of this fiberglass rebar reinforcement are shown in FIG. 7B and 8B.

[0150] A silicone mold 822 can also be placed on one or more sides of the mold to create a unique surface. An example of such an application is shown in FIG. 8C.Docket No.: BMI-1016PCT

[0151] Figure 9A depicts one embodiment of a biocementation system 900 for manufacturing a construction material using one or more biocementation processes. The biocementation system 900 includes a chamber 978 for processing a construction material under controlled environmental conditions, such as setting and / or adjusting the temperature, pressure, and humidity of the environment in which the construction material is manufactured. The environmental conditions applied to aggregate particles is controlled using the pressure, temperature, and humidity controller 990. The framework 992 is arranged within the chamber 978. Although only a single framework 992 is depicted within the chamber 978, additional frameworks may be simultaneously processed within the chamber 978. In some embodiments, the framework 992 and the chamber 978 may be tire same element. The construction material may be formed within the framework 992 while the controlled environmental conditions are applied. In some cases, the framework 992 comprises a supporting structure for aggregate particles within the framework 992. In one example, the framework 992 comprises an L-shaped framework or a rigid container for forming non-standard 3D shapes, such as L-barriers and artistically molded shapes. In another example, the framework 992 comprises a T-wall structure.

[0152] As depicted, the biocementation system 900 includes a fluid regulator 988 for applying a cementation solution and / or a feed solution to aggregate particles within the framework 992. The fluid regulator 988 may adjust the fluid pressure (and, in some embodiments, the fluid temperature) for a fluid being injected into the framework 992. As a fluid comprising the cementation reagent solution / feed solution (or another fluid, e.g.. an inoculation fluid, rinse fluid, etc.) is injected into the framework 992 within the processing chamber 978, the fluid regulator 988 may dynamically adjust the fluid flow rate as the construction material hardens or forms. The fluid regulator 988 may utilize a pump controller to adjust fluid pressure and direction of fluid flow. Nozzles, such as nozzle 989, may enable the fluid regulator to inject the fluid into the formwork though one or more inlets not depicted of the framework 992.

[0153] The fluid regulator 988 in communication with the computing system 901 may regulate a temperature of tire cementation solution applied to tire construction material within the framework 992 and regulate the rate at which the cementation solution is applied to the construction material. The fluid regulator 988 may include a heating element and / or a cooling element for regulating the temperature of the cementation solution applied to the construction material. The vibration, pressure, temperature, and humidity controller 990 is connected to a thermal conductor 984 (e.g., a metal grating or metal strip) that is in thermal communication with tire chamber 978. The thermal conductor 984 may be directly connected to or physicallyDocket No.: BMI-1016PCT contact the framework 992. A pallet 986 provides structural support for the construction material and the framework 992 within the chamber 978. The thermal conductor 984 is arranged between the pallet 986 and the chamber 978.

[0154] In some embodiments, the vibration, pressure, temperature, and humidity controller 990 may regulate the temperature of the construction material (e.g., the aggregate particles within the framework 992) within the chamber 978 via the heating or cooling of the thermal conductor 984. The vibration, pressure, temperature, and humidity controller 990 may regulate or adjust the temperahire of the construction material within the chamber 978 using temperahire regulated air flow. The vibration, pressure, temperature, and humidity controller 990 may adjust the ambient pressure within the chamber 978. The chamber 978 may fully enclose the framework 992 or may provide an open or vented environment.

[0155] The vibration, pressure, temperahire, and humidity’ controller 990 may regulate vibrations applied directly to or acoustically coupled to the framework 992 during feed and / or grow ing phases. During a growing phase, a feed solution is not pumped into the framework 992.

[0156] The bioccmcntation system 900 may cause pump 982 to provide cither recycled fluid or unrecycled fluid to the framework 992.

[0157] In some embodiments, the vibration, pressure, temperature, and humidity controller 990 may include a computing system, such as computing system 901. The computing system may include a network interface, processor, memory, and disk all in communication with each other. The network interface, processor, memory, and disk may comprise real components or virtualized components. In one example, the network interface, processor, memory, and disk are provided by a virtualized infrastructure or a cloud-based infrastructure. The network interface may allow the computing system to connect to one or more networks. As examples, the netw ork interface may comprise a wireless netw ork interface and / or a wired network interface. The processor may allow' the computing system to execute computer readable instructions stored in memory in order to perform 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 comprise 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 disk may comprise hardw are storage devices.

[0158] As depicted in Figure 9A, the system for manufacturing a construction material using one or more biocementation processes also includes a feed storage tank 972 for collecting left over portions of a cementation solution 973. The left over or unused portions of theDocket No.: BMI-1016PCT cementation solution 973 that passed through the framework 992 or were not utilized by the construction material within the framework 992 during a biocementation process may be collected and reused during subsequent biocementation processes. The filtered and / or recycled cementation solution 973 may be transferred to the fluid regulator 988 via a pump 982. In some cases, particulate matter within the cementation solution 973 collected by the feed storage tank 972 may be allowed to settle within the collection tank and therefore intaking fluid away from the bottom of the collection tank may provide filtering of the recycled cementation solution 973. In one example, the inlet tube for providing recycled cementation solution 973 to the pump 982 may be arranged at least 10 inches from the bottom of the feed storage tank 972 (e.g., the distance 971 between the bottom of the feed storage tank 972 and the inlet tube may be 12 inches). The inlet tube may include additional filtering for removing particulates from the recycled cementation solution 973.

[0159] In some cases, the system recirculates the cementation solution 973 and reinjects previously used fluid until a pH or electrical conductivity of the fluid reaches a particular pH (e.g., has risen above a pH of 7.9) and / or the electrical conductivity of the fluid falls below a threshold conductivity or resistance.

[0160] In some embodiments, the fluid comprising the cementation solution and / or a feed solution comprises urea and calcium salt (e.g., calcium chloride or other calcium2+-containing salts). In some embodiments, the concentration of urea within the fluid is greater than 700mM. In some embodiments, the concentration of urea within the fluid is betw een 700mM and 5M. In some embodiments, the concentration of calcium chloride within the fluid is greater than 700mM. In some embodiments, the concentration of calcium chloride within the fluid is between 700 mM and 5M.

[0161] In some embodiments, the feed solution comprises urea and / or calcium salt (e.g., calcium chloride or other calcium2+-containing salts) and has a molarity greater than greater than IM (e.g., between 1 M and 5 M, e.g.. between 1 M and 4 M, e.g., between IM and 3 M, e.g., between 1 M and 2 M, e.g., between 1.0 M and 1.5 M, e.g., between 1. 1 M and 1.4 M, e.g., between 1.2 M and 1.4 M, e.g., about 1.3 M). In some cases, the molarity of tire feed solution is between 1 M and 2 M (e.g., between 1.0 M and 1.5 M, e.g., between 1.1 M and 1.4 M, e.g., between 1.2 M and 1.4 M, e.g., about 1.3 M).

[0162] In some embodiments, the concentration of urea is about 0.7, 0.8, 0.9, 1.0, 1. 1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5 or 5.0M. In some embodiments, the concentration of calcium chloride is or is about 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.5. 3.0, 3.5, 4.0, 4.5 or 5.0M. In some embodiments, the concentration of the ureaDocket No.: BMI-1016PCT is about the same as the concentration of the calcium chloride. In some embodiments, tire concentration of the urea is different from the concentration of the calcium chloride. In some embodiments, a ratio of a first cementation reagent (e.g.. including calcium ions or a combination of metal ions, e.g., calcium chloride or a mixture of metal chlorides) to the second cementation reagent (e.g., urea or another source of carbonate ions) is from 1:2 to 2: 1 (e.g., about 2: 1, 1.9: 1 1.8: 1, 1.7: 1, 1.6: 1, 1.5:1, 1.4: 1, 1.3: 1, 1.2: 1, 1.1: 1, 1: 1, 1: 11, 1: 1.2, 1: 1.3, 1: 1.4, 1: 1.5, 1: 1.6, 1: 17, 1: 1.8, 1:1.9, or 1:2).

[0163] The concentration of urea in a cementation reagent solution (e.g., a feed solution, bath, etc.) may independently be about 0.1 M to about 4 M. The concentration of urea in a cementation reagent solution may independently be about 0.1 M to about 0.2 M, about 0.1 M to about 0.3 M, about 0. 1 M to about 0.4 M. about 0. 1 M to about 0.5 M, about 0.1 M to about 0.7 M, about 0.1 M to about 0.9 M, about 0.1 M to about 1 M, about 0.1 M to about1.2 M, about 0.1 M to about 1.5 M, about 0.1 M to about 2 M, about 0.1 M to about 3 M, about 0.2 M to about 0.3 M, about 0.2 M to about 0.4 M, about 0.2 M to about 0.5 M, about 0.2 M to about 0.7 M, about 0.2 M to about 0.9 M, about 0.2 M to about 1 M, about 0.2 M to about 1.2 M, about 0.2 M to about 1.5 M, about 0.2 M to about 2 M, about 0.2 M to about 3 M, about 0.3 M to about 0.4 M, about 0.3 M to about 0.5 M, about 0.3 M to about 0.7 M, about 0.3 M to about 0.9 M, about 0.3 M to about 1 M, about 0.3 M to about 1.2 M, about 0.3 M to about 1.5 M. about 0.3 M to about 2 M, about 0.3 M to about 3 M, about 0.4 M to about 0.5 M, about 0.4 M to about 0.7 M. about 0.4 M to about 0.9 M, about 0.4 M to about 1 M, about 0.4 M to about 1 .2 M, about 0.4 M to about 1 .5 M, about 0.4 M to about 2 M, about 0.4 M to about 3 M, about 0.5 M to about 0.7 M, about 0.5 M to about 0.9 M, about 0.5 M to about 1 M, about 0.5 M to about 1.2 M, about 0.5 M to about 1.5 M, about 0.5 M to about 2 M, about 0.5 M to about 3 M, about 0.7 M to about 0.9 M, about 0.7 M to about 1 M, about 0.7 M to about 1.2 M, about 0.7 M to about 1.5 M, about 0.7 M to about 2 M, about 0.7 M to about 3 M, about 0.9 M to about 1 M, about 0.9 M to about 1.2 M, about 0.9 M to about 1.5 M, about 0.9 M to about 2 M, about 0.9 M to about 3 M, about 1 M to about1.2 M, about 1 M to about 1.5 M, about 1 M to about 2 M, about 1 M to about 3 M, about1.2 M to about 1.5 M. about 1.2 M to about 2 M, about 1.2 M to about 3 M, about 1.5 M to about 2 M, about 1.5 M to about 3 M, about 2 M to about 3 M, about 2 M to about 4 M, about 2.5 M to about 4 M, or about 3 M to about 4 M. The concentration of urea in a cementation reagent solution may independently be about 0. 1 M. about 0.2 M, about 0.3 M, about 0.4 M, about 0.5 M, about 0.7 M, about 0.9 M. about 1 M. about 1.2 M, about 1.5 M, about 2 M, about 2.5 M, about 3 M, about 3.5 M, or about 4 M. The concentration of ureaDocket No.: BMI-1016PCT in a cementation reagent solution may independently be at least about 0.1 M, about 0.2 M, about 0.3 M, about 0.4 M, about 0.5 M, about 0.7 M. about 0.9 M. about 1 M, about 1.2 M, about 1.5 M, about 2 M, about 2.5 M, about 3 M, about 3.5 M, or about 4 M. The concentration of urea in a cementation reagent solution may independently be at most about 0.2 M, about 0.3 M, about 0.4 M, about 0.5 M, about 0.7 M, about 0.9 M, about 1 M, about 1.2 M, about 1.5 M, about 2 M, or about 4 M. In some embodiments, tire concentration of urea is from about 180 mM to about 330 mM. In some embodiments, the concentration of urea is from about 180 mM to about 190 mM, from about 190 mM to about 200 mM, from about 200 mM to about 210 mM, from about 210 mM to about 220 mM, from about 220 mM to about 230 mM, from about 230 mM to about 240 mM, from about 240 mM to about 250 mM, from about 250 mM to about 260 mM, from about 260 mM to about 270 mM, from about 270 mM to about 280 mM, from about 280 mM to about 290 mM, from about 290 mM to about 300 mM, from about 300 mM to about 310 mM. from about 310 mM to about 320 mM, or from about 320 mM to about 330 mM. In some embodiments, the concentration of urea is about 180, 190, 200, 210, 220. 230, 240. 250, 260. 270, 280. 290, 300. 310, 320. or 330 mM. In some embodiments, the concentration of urea is about 230 mM. In some embodiments, the concentration of urea is about 240 mM. In some embodiments, the concentration of urea is about 240 mM. In some embodiments, the concentration of urea is about 260 mM. In some embodiments, the concentration of urea is about 270 mM. In some embodiments, the concentration of urea is about 280 mM. The concentration of calcium ions, or the combined conentration of metal ions, in a cementation reagent solution (e.g.. a feed solution, bath, etc.) may independently be about 0.1 M to about 4 M. The concentration of calcium ions in a cementation reagent solution may independently be about 0. 1 M to about 0.2 M, about 0. 1 M to about 0.3 M, about 0. 1 M to about 0.4 M, about 0. 1 M to about 0.5 M, about 0. 1 M to about 0.7 M, about 0. 1 M to about 0.9 M, about 0. 1 M to about 1 M, about 0. 1 M to about 1.2 M, about 0. 1 M to about 1.5 M, about 0. 1 M to about 2 M, about 0. 1 M to about 3 M, about 0.2 M to about 0.3 M, about 0.2 M to about 0.4 M. about 0.2 M to about 0.5 M, about 0.2 M to about 0.7 M, about 0.2 M to about 0.9 M, about 0.2 M to about 1 M, about 0.2 M to about 1.2 M, about 0.2 M to about 1.5 M, about 0.2 M to about 2 M. about 0.2 M to about 3 M, about 0.3 M to about 0.4 M. about 0.3 M to about 0.5 M, about 0.3 M to about 0.7 M, about 0.3 M to about 0.9 M, about 0.3 M to about 1 M, about 0.3 M to about 1.2 M, about 0.3 M to about 1.5 M, about 0.3 M to about 2 M, about 0.3 M to about 3 M, about 0.4 M to about 0.5 M, about 0.4 M to about 0.7 M, about 0.4 M to about 0.9 M, about 0.4 M to about 1 M, about 0.4 M to about 1.2 M, about 0.4 M to about 1.5 M, about 0.4 M to about 2 M, about 0.4 M to about 3 M, about 0.5 M to about 0.7 M, about 0.5 M to about 0.9 M, about 0.5 M to about 1 M, about 0.5 M to about 1.2 M, about 0.5 M to about 1.5Docket No.: BMI-1016PCTM, about 0.5 M to about 2 M, about 0.5 M to about 3 M, about 0.7 M to about 0.9 M, about 0.7 M to about 1 M, about 0.7 M to about 1.2 M, about 0.7 M to about 1.5 M, about 0.7 M to about 2 M, about 0.7 M to about 3 M, about 0.9 M to about 1 M, about 0.9 M to about 1.2 M, about 0.9 M to about 1.5 M, about 0.9 M to about 2 M, about 0.9 M to about 3 M. about 1 M to about 1.2 M, about 1 M to about 1.5 M, about 1 M to about 2 M, about 1 M to about 3 M, about 1.2 M to about 1.5 M, about 1.2 M to about 2 M, about 1.2 M to about 3 M, about 1.5 M to about 2 M, about 1.5 M to about 3 M, about 2 M to about 3 M, about 2 M to about 4 M, about 2.5 M to about 4 M, or about 3 M to about 4 M. The concentration of calcium ions, or the combined concentration of metal ions, in a cementation reagent solution may independently be about 0.1 M, about 0.2 M, about 0.3 M, about 0.4 M, about 0.5 M, about 0.7 M, about 0.9 M. about 1 M, about 1.2 M, about 1.5 M. about 2 M, or about 3 M. The concentration of calcium ions, or the combined concentration of metal ions, in a cementation reagent solution may independently be at least about 0.1 M, about 0.2 M, about 0.3 M, about 0.4 M, about 0.5 M, about 0.7 M, about 0.9 M, about 1 M, about 1.2 M, about 1.5 M, about 2 M, or about 3 M. In some embodiments, the concentration of calcium chloride, or the combined concentration of metal ions, is from about 180 mM to about 330 mM. In some embodiments, the concentration of calcium chloride, or the combined concentration of metal ions, is from about 180 mM to about 190 mM, from about 190 mM to about 200 mM, from about 200 mM to about 210 mM, from about 210 mM to about 220 mM, from about 220 mM to about 230 mM, from about 230 mM to about 240 mM, from about 240 mM to about 250 mM, from about 250 mM to about 260 mM, from about 260 mM to about 270 mM, from about 270 mM to about 280 mM, from about 280 mM to about 290 mM, from about 290 mM to about 300 mM, from about 300 mM to about 310 mM, from about 310 mM to about 320 mM, or from about 320 mM to about 330 mM. In some embodiments, the concentration of calcium chloride, or tire combined concentration of metal ions, is about 180, 190. 200, 210, 220, 230, 240, 250, 260, 270, 280, 290. 300, 310, 320, or 330 mM. In some embodiments, the concentration of calcium chloride is about 230 mM. In some embodiments, the concentration of calcium chloride is about 240 mM. In some embodiments, the concentration of calcium chloride is about 240 mM. In some embodiments, the concentration of calcium chloride is about 260 mM. In some embodiments, tire concentration of calcium chloride is about 270 mM. In some embodiments, the concentration of calcium chloride is about 280 mM. In some embodiments, the concentration of calcium chloride, or tire combined concentration of metal ions, is from 250 mM to 1000 mM, e.g., from 250 to 750 mM, from 400 mM to 600 mM, from 500 mM to 800 mM, or from 750 mM to 1000 mM. In some embodiments, the concentration of calcium chloride, or the combined concentration of metal ions, is between 1 M and 2 M.Docket No.: BMI-1016PCT

[0164] Figure 9B depicts one embodiment of various components of the computing system 901 in Figure 9A. The components within the computing system 901 may comprise real hardware computing devices or virtual computing devices, such as one or more virtual machines. As depicted, the computing system 901 includes hardware-level components and software-level components. The hardware-level components may include one or more processors 170, one or more memories 171, and one or more disks 172. The one or more processors 170 may include one or more processing units, such as one or more CPUs, one or more GPUs, and / or one or more NPUs. The one or more memories 171 may comprise one or more types of memory (e.g., RAM, SRAM, DRAM, EEPROM, Flash). The one or more disks 172 may include a hard disk drive and / or a solid-state drive. Both the one or more memories 171 and the one or more disks 172 may comprise hardware storage devices. A storage device may correspond to the one or more memories 171 or the one or more disks 172.

[0165] The software-level components may include software applications and computer programs. The feeding controller 191 and fluid control application 192 may be stored or implemented using software or a combination of hardware and software. In some cases, the software-level components are run using a dedicated hardware server. In other cases, the software-level components may be run using a virtual machine or containerized environment running on a plurality of machines. In various embodiments, the software-level components may be run from the cloud (e.g., the software-level components may be deployed using a cloudbased compute and storage infrastructure).

[0166] As depicted in Figure 9B, the software-level components may also include virtualization layer processes, such as virtual machine 173, hypervisor 174. container engine 175, and host operating system 176. The hypervisor 174 may comprise a native hypervisor (or bare-metal hypervisor) or a hosted hypervisor (or type 2 hypervisor). The hyperv isor 174 may provide a virtual operating platform for running one or more virtual machines, such as virtual machine 173. A hypervisor may comprise software that creates and runs virtual machine instances. Virtual machine 173 may include a plurality of virtual hardware devices, such as a virtual processor, a virtual memory, and a virtual disk. The virtual machine 173 may include a guest operating system that has the capability to run one or more software applications. The virtual machine 173 may run the host operation system 176 upon which the container engine 175 may run.

[0167] The container engine 175 may run on top of the host operating system 176 in order to ran multiple isolated instances (or containers) on the same operating system kernel of the host operating system 176. Containers may facilitate virtualization at the operating system level andDocket No.: BMI-1016PCT may provide a virtualized environment for running applications and their dependencies. Containerized applications may comprise applications that run within an isolated runtime environment (or container). The container engine 175 may acquire a container image and convert the container image into running processes. In some cases, the container engine 175 may group containers that make up an application into logical units (or pods). A pod may contain one or more containers and all containers in a pod may run on the same node in a cluster. Each pod may serve as a deployment unit for the cluster. Each pod may run a single instance of an application.

[0168] In some embodiments, the depicted components of the computing system 901 including the feeding controller 191 and the vibration control application 192 are implemented in tire cloud or in a virtualized environment that allows virtual hardware to be created and decoupled from the underlying physical hardware.

[0169] The feeding controller 191 may configure or adjust the amount and type (e.g., unrecy cled or recycled feed solution) of feed solution applied to tire framework 992.

[0170] The vibration control application 192 may configure or adjust the amount of vibration applied to tire framew ork 992 during feed and / or growing phases.

[0171] Figures 9C-9H depict embodiments related to various systems and processes for manufacturing a construction material.

[0172] The disclosure herein encompasses the subject matter set forth in the following clauses:

[0173] Clause 1. A method of producing a construction material, comprising: adding a plurality of aggregate particles into a supporting structure, thereby forming a formed plurality of aggregate particles: flowing a fluid comprising cementation reagents through the formed plurality of aggregate particles; and reacting the cementation reagents with a biological organism or an enzyme within the fluid or within the formed plurality- of aggregate particles for a sufficient time to consolidate or bind at least a portion of the formed plurality7of aggregate particles, thereby producing the construction material.

[0174] Clause 2. The method of clause 1, further comprising: preheating the plurality of aggregate particles prior to adding the plurality of aggregate particles into the supporting structure.Docket No.: BMI-1016PCT

[0175] Clause 3. The method of clause 1, further comprising: heating the plurality of aggregate particles while the plurality’ of aggregate particles are contained within the supporting structure.

[0176] Clause 4. The method of clause 1, further comprising: vibrating the plurality’ of aggregate particles while tire plurality of aggregate particles is contained within tire supporting structure.

[0177] Clause 5. The method of clause 1, further comprising: vibrating the plurality’ of aggregate particles prior to inoculating the plurality of aggregate particles.

[0178] Clause 6. The method of clause 1, further comprising: vibrating the plurality’ of aggregate particles subsequent to inoculating the plurality of aggregate particles.

[0179] Clause 7. The method of clause 1, further comprising: vibrating the plurality’ of aggregate particles until a green density has reached a threshold density (e.g., until at least 2.0 g / cc).

[0180] Clause 8. The method of clause 1, further comprising: vibrating the plurality’ of aggregate particles during a feeding phase (i.c.. when feed solution is being pumped into or flowing through the supporting structure) while the plurality’ of aggregate particles are contained within the supporting structure.

[0181] Clause 9. The method of clause 1, further comprising: vibrating the plurality' of aggregate particles during a growing phase (i.e., when feed solution is not being pumped into or flowing through the supporting structure) while the plurality' of aggregate particles are contained within the supporting structure.

[0182] Clause 10. The method of clause 1, wherein: the construction material includes a reinforcement structure or material.

[0183] Clause 11. The method of clause 1, wherein: the construction material includes a coated rebar mesh or a coated rebar 3D mesh.

[0184] Clause 12. The method of clause 1, wherein: the construction material includes an epoxy coated rebar, epoxy coated steel rebar, or polymer coated rebar.

[0185] Clause 13. The method of clause 1, wherein: the construction material includes a basalt fiber composite rebar or a basalt coated rebar.

[0186] Clause 14. The method of clause 1, wherein: the construction material includes a rebar structure, wherein tire rebar structure comprises a non-metal rebar structure without aDocket No.: BMI-1016PCT coating (e.g., a basalt fiber polymer composite rebar without a coating), a non-metal rebar structure with a coating (e.g., a basalt fiber polymer composite rebar that is coated with sand or a lacquer).

[0187] Clause 15. The method of clause 1, further comprising: combining the plurality of aggregate particles with a reinforcement structure while the plurality of aggregate particles is contained within the supporting structure.

[0188] Clause 16. The method of clause 1, further comprising: adding the plurality of aggregate particles into the supporting structure while a reinforcement structure is within the supporting structure.

[0189] Clause 17. The method of clause 16. further comprising: vibrating the plurality of aggregate particles via acoustic means or using a vibration element mechanically or acoustically coupled to the reinforcement structure.

[0190] Clause 18. The method of any of the preceding clause 1-17. wherein: the flowing comprises flowing the fluid using a source of pressure (e.g., a pump such as a diaphragm pump or a piston pump).

[0191] Clause 19. The method of any of the preceding clause 1-17, wherein: the flowing comprises flowing the fluid through the supporting structure or the formed plurality of aggregate particles during a feeding phase (e.g., when feed solution is being pumped into or flowing through the supporting structure).

[0192] Clause 20. The method of any of the preceding clause 1-17, further comprising: during a growing phase (e.g., when feed solution is not being pumped into or flowing through the supporting structure), maintaining fluid pressure to prevent backflow.

[0193] Clause 21. The method of any of the preceding clause 1-17, wherein: the flowing comprises flowing an unrccyclcd portion of the fluid.

[0194] Clause 22. The method of any of the preceding clause 1-17, wherein: the flowing comprises flowing a recycled portion of the fluid.

[0195] For purposes of this document, it should be noted that the dimensions of tire various features depicted in the figures may not necessarily be drawn to scale.

[0196] For purposes of this document, reference in the specification to "an embodiment,” “one embodiment,” “some embodiments,” “another embodiment,” and other variations thereof may be used to describe various features, functions, or structures that are included in at leastDocket No.: BMI-1016PCT one or more embodiments and do not necessarily refer to tire same embodiment unless tire context clearly dictates otherwise.

[0197] For purposes of this document, a connection may be a direct connection or an indirect connection (e.g., via another part). In some cases, when an element is referred to as being connected or coupled to another element, the element may be directly connected to the other element or indirectly connected to the other element via intervening elements. When an element is referred to as being directly connected to another element, then there are no intervening elements between the element and the other element.

[0198] For purposes of this document, the term “based on” may be read as “based at least in part on.”

[0199] For purposes of this document, without additional context, use of numerical terms such as a “first” object, a “second” object, and a “third” object may not imply an ordering of objects, but may instead be used for identification purposes to identify or distinguish separate objects.

[0200] For purposes of this document, the term “set” of objects may refer to a “set” of one or more of tire objects.

[0201] For purposes of this document, the phrases “a first object corresponds with a second object” and “a first object corresponds to a second object” may refer to the first object and the second object being equivalent, analogous, or related in character or function.

[0202] For purposes of this document, the term “or” should be interpreted in the conjunctive and the disjunctive. A list of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among the items, but rather should be read as “and / or” unless expressly stated otherwise. The terms “at least one,” “one or more,” and “and / or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. The phrase “A and / or B” covers embodiments having element A alone, element B alone, or elements A and B taken together. The phrase “at least one of A, B, and C” covers embodiments having element A alone, element B alone, element C alone, elements A and B together, elements A and C together, elements B and C together, or elements A, B, and C together. The indefinite articles “a” and “an,” as used herein, should typically be interpreted to mean “at least one” or “one or more,” unless expressly stated otherwise.

[0203] For purposes of this document, whenever the term “at least,” “greater than,” or “greater than or equal to” precedes tire first numerical value in a series of two or more numerical values, the term “at least,” “greater than” or “greater than or equal to” applies to each of theDocket No.: BMI-1016PCT numerical values in that series of numerical values. 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.

[0204] For purposes of this document, whenever tire term “no more than,'’ “less than,” or “less than or equal to” precedes the first numerical value in a series of two or more numerical values, the tern “no more than,” “less than.” or “less than or equal to” applies to each of the numerical values in that series of numerical values. 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.

[0205] Some embodiments disclosed herein contemplate numerical ranges. When ranges are present, the ranges include the range endpoints. Additionally, every sub range and value within the range is present as if explicitly written out. The term “about”, “approximately”, or “substantially” may mean within an acceptable error range for the particular value, which may depend in part on how the value is measured or determined, e.g., the limitations of tire measurement system. For example, “about” may mean within one or more than one 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. Where particular values are described in the application and claims, unless otherwise stated the term “about” meaning within an acceptable error range for the particular value may be assumed.

[0206] 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 abovedetailed description. In general, in the following claims, the terms used should not be construed to limit the claims to tire specific embodiments disclosed in the specification and the 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 disclosure.

Claims

Docket No.: BMI-1016PCTCLAIMS1. A method of producing a construction material, comprising: adding a plurality of aggregate particles into a supporting structure, thereby forming a formed plurality of aggregate particles; flowing a fluid comprising cementation reagents through the formed plurality of aggregate particles; and reacting the cementation reagents with a biological organism or an enzyme within the fluid or within the formed plurality of aggregate particles for a sufficient time to consolidate or bind at least a portion of the fonned plurality of aggregate particles, thereby producing tire construction material.

2. The method of claim 1, further comprising: preheating the plurality of aggregate particles prior to adding the plurality of aggregate particles into the supporting structure.

3. The method of claim 1, further comprising: heating the plurality’ of aggregate particles while the plurality of aggregate particles is contained within the supporting structure.

4. The method of claim 1, further comprising: vibrating the plurality of aggregate particles while the plurality of aggregate particles is contained within the supporting structure.

5. The method of claim 1, further comprising: vibrating the plurality of aggregate particles prior to inoculating the plurality of aggregate particles.

6. The method of claim 1, further comprising: vibrating the plurality of aggregate particles subsequent to inoculating the plurality of aggregate particles.Docket No.: BMI-1016PCT7. The method of claim 1, further comprising: vibrating the plurality of aggregate particles until a green density has reached a threshold density of at least 1.80 g / cc.

8. The method of claim 1, further comprising: vibrating tire plurality of aggregate particles during a feeding phase when feed solution is flowing through the supporting structure.

9. The method of claim 1, further comprising: vibrating the plurality of aggregate particles during a growing phase when feed solution is not flowing through the supporting structure.

10. The method of claim 1, wherein: the construction material includes a reinforcement structure or material; the supporting structure comprises a structure that at least partially encloses the plurality’ of aggregate particles or comprises a rigid mold that includes holes; the supporting structure is coupled to an acoustic or mechanical vibratory element; and the inoculating the plurality of aggregate particles includes inoculating the plurality of aggregate particles with microorganisms, inoculating the plurality of aggregate particles by recirculating a culture through the plurality of aggregate particles, or adding microorganisms to the plurality of aggregate particles using a feeding or pumping system.

11. The method of claim 1, wherein: the construction material includes a coated rebar mesh or a coated rebar 3D mesh.

12. The method of claim 1, wherein: the construction material includes an epoxy coated rebar, epoxy coated steel rebar, or polymer coated rebar.

13. The method of claim 1, wherein: the construction material includes a basalt fiber composite rebar or a basalt coated rebar.Docket No.: BMI-1016PCT14. The method of claim 1, wherein: the construction material includes a rebar structure, wherein the rebar structure comprises a non-metal rebar structure with or without a coating.

15. The method of claim 1, further comprising: combining the plurality of aggregate particles with a reinforcement structure while the plurality of aggregate particles is contained within the supporting structure.

16. The method of claim 1, further comprising: adding the plurality of aggregate particles into tire supporting structure while a reinforcement structure is within the supporting structure.

17. The method of claim 16, further comprising: vibrating the plurality of aggregate particles via acoustic means or using a vibration element mechanically or acoustically coupled to the reinforcement structure.

18. The method of claims 1, wherein: tire flowing comprises flowing the fluid using a source of pressure.

19. The method of claim 1, wherein: the flowing comprises flowing the fluid through the supporting structure or the formed plurality7of aggregate particles during a feeding phase.

20. The method of claims 1, further comprising: during a growing phase maintaining fluid pressure to prevent backflow.

21. The method of claim 1, wherein: the flowing comprises flowing an unrecycled portion of the fluid.

22. The method of claim 1, wherein: the flow ing comprises flowing a recycled portion of the fluid.

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