NSF Award
1534787
This Small Business Innovation Research Phase II project is focused on the continued development of biologically grown masonry units as a commercially-viable and sustainable alternative to traditional fired masonry materials. This product is grown in ambient temperatures utilizing a natural calcium carbonate cement formation induced by a urease-producing microorganism. The Phase II project will focus on material testing and further optimization and cost reduction of biocement products, with the intention of demonstrating pilot manufacturing and rapid commercialization via licensee manufacturers. Using biologic products and fermentation procedures developed in the Phase I effort, improvements will be made to scale up manufacturing and reduce cost in the manufacturing process. The commercial potential of this technology is critically dependent on achieving cost and performance parity, if not superiority, with traditional materials. Each year, 1.23 trillion fired bricks are produced globally for use in construction, resulting in over 800 million tons of carbon emissions. The societal impacts of this research would include a dramatic reduction in these emissions, as well as a corresponding reduction in industrial by-product waste. This project will enhance the technological understanding for commercial viability and test data including durability and physical performance.<br/><br/>Technical objectives for this effort include evaluation of the resulting biocement masonry products through rigorous American Society of Testing Materials (ASTM) testing methods, reduction of raw material costs through continued optimization, creation of in-house production capability for the requisite biologic product, and the creation and testing of a manufacturing process suitable for transition to licensees. Main focus areas of the Phase II project include rigorous material testing for physical performance, weathering and durability, in-house production of robust raw material constituents, and commercial testing coupled with pilot manufacturing. Rigorous ASTM testing methods will be done at two accredited labs, and labor requirements will be reduced via the adoption of lean automation in the production process. Additionally, the utilization of existing material handing manufacturing equipment at licensee facilities, where possible, will be evaluated. Expected project results will include a comprehensive statistical analysis of multiple physical samples, as well as a corresponding failure analysis. Additional expected deliverables include the successful commission of in-house pilot scale manufacturing for biocement constituents as a simplified additive to be used by commercial partners and licensees.
