Methods for the Manufacture of Masonry

Abstract

The invention is directed to compositions and methods for the manufacture of pigmented solids structures for which can be used for construction and/or decoration. Manufacturing comprises fixing one or more pigments to an aggregate material such as crushed rock, stone or sand. The pigmented aggregate is incubated with urease or urease producing microorganisms, an amount of a nitrogen source such as urea, and an amount of calcium source such as calcium chloride forming calcite bridges between particles of aggregate. The resulting solid has a hardness and colorfastness for most any construction material. Using selected aggregate and pigment, the process also provides for the manufacture of simulated-stone materials such as clay or granite bricks or blocks, marble counter-tops, and more. The invention is also directed to composition containing microorganisms and pigment as kits that can be added to most any aggregate materials.

1 . A solid structure comprising a plurality of layers of aggregate particles, wherein sand is one aggregate particle, and wherein the sand at the borders of each adjacent layer is bonded by calcite bonds formed from urease enzyme activity in the presence of a calcium source and a nitrogen source to form a solid structure. 
     
     
         2 . The solid structure of  claim 1  formed into a desired shape and size. 
     
     
         3 . The solid structure of  claim 1 , further comprising a textured surface. 
     
     
         4 . The solid structure of  claim 1 , wherein urea is the nitrogen source. 
     
     
         5 . The solid structure of  claim 1 , wherein the calcium source is selected from one of more of calcium chloride, calcium acetate, calcium phosphate, calcium carbonate, calcium lactate, or a calcium salt. 
     
     
         6 . A method of producing a layered construction material comprising:
 providing a formwork of desired shape and size;   mixing aggregate materials wherein one aggregate material is sand with a composition containing urease or urease-producing cells, a nitrogen source, and a calcium source forming a mixture;   adding the mixture into the formwork and incubating the mixture at room temperature to solidify a first layer of the aggregate materials in the form;   layering at least one subsequent layer of the mixture on top of the first layer, wherein the sand present in the borders of each adjacent layer is bonded by calcite bonds formed from the urease enzyme activity; and   curing the combination of ingredients at room temperature thereby creating the solid component.   
     
     
         7 . The method of  claim 6 , wherein the nitrogen source is urea, 
     
     
         8 . The method of  claim 6 , wherein the calcium source is selected from one or more of calcium chloride, calcium acetate, calcium phosphate, calcium carbonate, calcium lactate, or a calcium salt. 
     
     
         9 . The method of  claim 6 , wherein the formwork comprises a textured surface capable of forming a textured surface on the construction material. 
     
     
         10 . The method of  claim 6 , further comprising adding a nutrient capable of promoting urease enzyme activity. 
     
     
         11 . The method of  claim 6 , wherein the urease-producing cells comprise one or more species, subspecies, strains, serotypes or recombinant forms of  Sporosarcina pasteurii, Sporosarcina ureae, Proteus vulgaris, Bacillus sphaericus, Myxococcus xanthus, Proteus mirabilis, Bacillus megaterium , and  Helicobacter pylori.    
     
     
         12 . A method for manufacture of a solid component comprising:
 providing a formwork and, in any order, adding an aggregate and a composition containing urease or urease-producing cells, urea and calcium ions, together forming a combination of ingredients;   mixing the combination of ingredients; and   curing the combination of ingredients thereby creating the solid component.   
     
     
         13 . The method of  claim 12 , wherein the solid component is a concrete masonry unit, a cinder block, a brick, a foundation block, a breeze block, a hollow block, a solid block, a besser block, a clinker block, a high or low density block, an aerated block, a tile, a veneer, a rectangular, a square, rounded, an oval or an irregular shape. 
     
     
         14 . The method of  claim 12 , wherein the solid component is part of a multi-component structure selected from the group consisting of a wall, a structural member, a building, a road, or a combination thereof. 
     
     
         15 . The method of  claim 12 , wherein the aggregate, the urease and the calcium are mixed prior to being added to the formwork. 
     
     
         16 . The method of  claim 12 , wherein the aggregate, the urease and the calcium ions are added simultaneously or sequentially. 
     
     
         17 . The method of  claim 12 , wherein curing comprises atmospheric conditions and ambient temperatures. 
     
     
         18 . The method of  claim 12 , wherein the enzyme producing cells are bacteria selected from the group consisting of  Sporosarcina pasteurii, Sporosarcina ureae, Proteus vulgaris, Bacillus sphaericus, Myxococcus xanthus, Proteus mirabilis, Helicobacter pylori  and variants, mutations, genetically engineered cells, and combinations thereof. 
     
     
         19 . The method of  claim 12 , wherein calcium ions are selected from the group consisting of calcium chloride, calcium acetate, calcium phosphate, calcium carbonate, calcium lactate, a calcium salt, and a combination thereof. 
     
     
         20 . A solid component manufactured by the method of  claim 12 .