Methods for making construction materials using enzyme producing bacteria

• US 9,199,880 B2
• Filed: 05/06/2014
• Issued: 12/01/2015
• Est. Priority Date: 04/27/2010
• Status: Active Grant

• Current Assignee: bioMASON, Inc.
• Original Assignee: bioMASON, Inc.
• Inventors: Dosier, Ginger K.
• Primary Examiner(s): THEISEN, MARY LYNN F
• Application Number:
  US14/270,846
• Publication Number:
  US 20140239535A1
• Time in Patent Office: 574 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/305 Titanium oxide, e.g. titanates
• CPC Class Codes: C04B 2103/0001 Living organisms, e.g. microorganisms, or enzymes
• CPC Class Codes: C04B 2103/0067 the ingredients being formed in situ by chemical reactions or conversion of one or more of the compounds of the composition
• CPC Class Codes: C04B 2111/00017 Aspects relating to the protection of the environment
• CPC Class Codes: C04B 22/124 Chlorides of ammonium or of the alkali or alkaline earth metals, e.g. calcium chloride
• CPC Class Codes: C04B 24/12 Nitrogen containing compounds organic derivatives of hydrazine hydrazine C04B22/00
• CPC Class Codes: C04B 24/126 Urea
• CPC Class Codes: C04B 24/14 Peptides; Proteins; Derivatives thereof
• CPC Class Codes: C04B 28/10 Lime cements or magnesium oxide cements
• CPC Class Codes: C04B 35/632 Organic additives
• CPC Class Codes: C04B 40/0039 Premixtures of ingredients
• CPC Class Codes: C12N 9/80 acting on amide bonds in linear amides (3.5.1)
• CPC Class Codes: C12P 1/04 by using bacteria
• CPC Class Codes: C12Y 305/01005 Urease (3.5.1.5)

Abstract

Methods for producing construction material utilizing loose pieces of aggregate (30), enzyme producing bacteria, an amount of urea and an amount of calcium ions. A first solution is prepared which includes urease which is formed by enzyme producing bacteria. A second solution is prepared which includes urea and calcium ions. The first and second solutions are added to the loose aggregate (30). The calcium ions contribute to the formation of calcium carbonate wherein the calcium carbonate fills and bonds between at least some of the gaps between the loose pieces of aggregate forming a solid construction material (92).

Claims

1. A method for producing construction material comprising:

combining water, a performance enhancing material, urea, calcium ions and urease or urease-producing microorganisms to form an aqueous mixture;

combining the aqueous mixture with;

loose pieces of aggregate under conditions that allow for the formation of calcium carbonate; and

;

forming a solid material.

2. The method of claim 1, wherein the performance enhancing material provides increased strength to the solid material.

3. The method of claim 1, wherein the performance enhancing material comprises titanium.

4. The method of claim 1, wherein the performance enhancing material provides for the absorption of pollutants.

5. The method of claim 1, wherein the performance enhancing material provides increased transparency to the solid material.

6. The method of claim 1, wherein the performance enhancing material comprises glass.

7. The method of claim 1, wherein the performance enhancing material provides increased insulative properties to the solid material.

8. The method of claim 1, wherein the performance enhancing material comprises fibers.

9. The method of claim 1, wherein the urease-producing microorganisms are selected from the group consisting essentially of natural or recombinant Sporosarcina pasteurii, Sporosarcina ureae, Proteus vulgaris, Bacillus sphaericus, Myxococcus xanthus, Proteus mirabilis, Helicobacter pylori and combinations thereof.

10. The method of claim 1, wherein the loose pieces of aggregate are selected from the group consisting of sand, glass beads, recycled glass foam, fly ash composite, soil, stones, basalt, fibers and mixtures thereof.

11. The method of claim 1, wherein the conditions include one or more of a temperature, an atmosphere, a neutral or alkaline pH and a period of time.

12. The method of claim 1, wherein the temperature is below 40°

C.

13. The method of claim 11, wherein the atmosphere comprises carbon dioxide.

14. The method of claim 11, wherein the neutral or alkaline pH is 7.25.

15. The method of claim 11, wherein the period of time is from 4-12 hours.

16. The method of claim 1, wherein the solid material is a masonry unit.

17. The method of claim 16, wherein the masonry unit is a brick.

18. The method of claim 1, further comprising a formwork in which the aqueous mixture and loose aggregate are combined.

19. A masonry unit produced by the method of claim 1.

20. The masonry unit of claim 19, which comprises a brick.

21. A method of producing construction material comprising:

combining water, a performance enhancing material, urea, calcium ions and urease or urease-producing microorganisms to form an aqueous mixture;

combining the aqueous mixture with a structure to form calcium carbonate; and

forming a veneer or layer of calcium carbonate on the structure.

22. The method of claim 21, wherein the performance enhancing material provides increased strength to the structure.

23. The method of claim 21, wherein the performance enhancing material comprises titanium.

24. The method of claim 21, wherein the performance enhancing material provides for the absorption of pollutants.

25. The method of claim 21, wherein the performance enhancing material provides increased transparency to the structure.

26. The method of claim 21, wherein the performance enhancing material comprises glass.

27. The method of claim 21, wherein the performance enhancing material provides increased insulative properties to the structure.

28. The method of claim 21, wherein the performance enhancing material comprises fibers.

29. The method of claim 21, further comprising a formwork in which the aqueous mixture is combined with the structure.

30. A masonry unit produced by the method of claim 21.