EP4479362A1 - Enzymatic construction material for repair and corrosion resistance and durability - Google Patents
Enzymatic construction material for repair and corrosion resistance and durabilityInfo
- Publication number
- EP4479362A1 EP4479362A1 EP23756863.9A EP23756863A EP4479362A1 EP 4479362 A1 EP4479362 A1 EP 4479362A1 EP 23756863 A EP23756863 A EP 23756863A EP 4479362 A1 EP4479362 A1 EP 4479362A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- ecm
- enzyme
- carbonic anhydrase
- samples
- gelatin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
- C04B41/61—Coating or impregnation
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/02—Treatment
- C04B20/023—Chemical treatment
- C04B20/0232—Chemical treatment with carbon dioxide
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/04—Carboxylic acids; Salts, anhydrides or esters thereof
- C04B24/06—Carboxylic acids; Salts, anhydrides or esters thereof containing hydroxy groups
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/12—Nitrogen containing compounds organic derivatives of hydrazine
- C04B24/14—Peptides; Proteins; Derivatives thereof
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/4505—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
- C04B41/4535—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied as a solution, emulsion, dispersion or suspension
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5007—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with salts or salty compositions, e.g. for salt glazing
- C04B41/5011—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with salts or salty compositions, e.g. for salt glazing containing halogen in the anion
- C04B41/5012—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with salts or salty compositions, e.g. for salt glazing containing halogen in the anion chlorides
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5076—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with masses bonded by inorganic cements
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12N—MICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA
- C12N9/00—Enzymes; Proenzymes; Compositions thereof; Processes for preparing, activating, inhibiting, separating or purifying enzymes
- C12N9/88—Lyases (4.)
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/26—Corrosion of reinforcement resistance
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/72—Repairing or restoring existing buildings or building materials
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12Y—ENZYMES
- C12Y402/00—Carbon-oxygen lyases (4.2)
- C12Y402/01—Hydro-lyases (4.2.1)
- C12Y402/01001—Carbonate dehydratase (4.2.1.1), i.e. carbonic anhydrase
Definitions
- the fluidic mixture Prior to curing, the fluidic mixture may be cast or poured into any suitable shape; about 90 minutes after mixing with water it begins to cure into the molded shape and manifests substantial compressive strength and mass.
- concrete is the most consumed material on earth as it has been calculated that three tons per year are used per person. Every year, waste concrete from construction and carbon dioxide emission from cement production and transport is increasing, and concrete alone contributes to 9% of total CO 2 emission.
- the average temperatures in the Arctic have been rising faster than anywhere on earth, this is due to the rise in sea level caused by the greenhouse effect. climate change caused by increased CO 2 levels due to human activity is the biggest existential threat facing the world. Therefore, reducing carbon dioxide emissions to reduce the greenhouse effect is an urgent task.
- An aspect of the invention herein provides a method for repairing at least one fracture or notch in a cementitious surface, the method comprising: treating at least one fracture or notch in the cementitious surface to at least one carbonic anhydrase preparation, the preparation containing carbonic anhydrase immobilized non-covalently on a particulate substrate or embedded in a semi-solid bead matrix; and subjecting the cementitious treated surface to ambient conditions of atmospheric carbon dioxide and temperature, thereby repairing the fracture.
- An embodiment of the method further includes repeating the treatment the at least one fracture or notch with the carbonic anhydrase preparation and subjecting the treated surface to the ambient condition. For repeating the treating step, the method further includes air drying the treated cementitious surface before repeating the treating.
- the carbonic anhydrase preparation further includes at least one additional component selected from: a native carbonic anhydrase, calcium ions, a buffer, and water.
- the native carbonic anhydrase has an amino acid sequence found in nature, as this enzyme is found throughout the range of biological organisms, both in prokaryotes and eukaryotes, and the enzyme suitable for methods and materials herein may be obtained from any source.
- the carbonic anhydrase preparation particulate substrate is in various alternative embodiments one or more of a silicone bead, silicon dioxide, a silica gel, disiloxane, silicic acid, silanol, an organic silicon compound, sand, grit, cellulose, and a cellulose derivative.
- the carbonic anhydrase preparation semi-solid bead matrix is in various embodiments prepared from at least one selected from: a hydrogel, an agar, and a gelatin.
- the CA is recombinantly produced.
- the CA is a purified or partially purified from a food industry byproduct or a fermentation byproduct.
- the carbonic anhydrase is recombinantly produced or is prepared directly from a natural biological source, as widespread use of the enzyme will require bulk quantities, and the source will be dictated by economic factors. Carbonic anhydrase is found in organisms from bacteria to mammals.
- carbonic anhydrase in various embodiments is purified or is semi-purified or is a crude extract, for example, produced from a crude lysate of cells by organic solvent extraction or by a small number of ammonium sulfate precipitations.
- the carbonic anhydrase is purified or partially purified from a biological source, for example, is a mammalian enzyme byproduct of the meat industry produced, for example, from bovine blood or is a bacterial enzyme or yeast enzyme byproduct of antibiotic or high-value protein fermentation.
- Certain applications of the method may involve obtaining carbonic anhydrase from a bacterial species that is a thermophilic or a xerophilic species.
- the recombinant carbonic anhydrase may be produced by expression of the gene encoding the enzyme, expressed in E. coli, in Streptomyces lividans, or in Saccharomyces cerevisiae, for example, secreted into the fermentation medium.
- Another aspect of the invention herein provides a method for improving durability and corrosion resistance of a cementitious surface, the method including steps of: contacting a cement mixture prior to curing to at least one carbonic anhydrase (CA) preparation to form an enzyme-cement mixture (ECM); applying the ECM to a surface and subjecting the ECM on the surface to an ambient atmosphere and curing, thereby improving durability and corrosion resistance by reducing porosity of a resulting CA-contacted cementitious surface in comparison to a control cement not CA-contacted.
- CA carbonic anhydrase
- ECM enzyme-cement mixture
- the method uses the carbonic anhydrase preparation with the enzyme embedded or immobilized non-covalently on a particulate substrate selected from a silicone bead, a silica gel, sand, grit, cellulose, cellulose derivative; or the carbonic anhydrase preparation comprises CA embedded in a semi-solid bead matrix comprising a hydrogel or in gelatin. Embedding or immobilizing or attaching the CA provides better distribution in the cement mixture in comparison to a CA solution. While gelatin has a low transition temperature from solid or semi-solid to liquid, association of the enzyme even with gelatin in a liquid form is beneficial to the distribution of enzyme in the resulting cementitious product.
- Matrix materials with higher melting points such as agar can be used in low percent preparations, for example less than 1% or 2% agar, and agar/gelatin mixtures are also envisioned.
- the ECM materials herein and methods of making the ECM provide for the resulting CA-contacted cementitious surface having reduced permeability to deleterious environmental corrosive agents.
- the reduced porosity results from calciferous crystallization shown herein to be due to the action of the carbonic anhydrase.
- An important consequence of reducing porosity of the resulting cementitious surfaces is decreased permeation by deleterious salt ions including chloride salts. Corrosion by chloride ions of iron rebars in reinforced concrete used in construction is thereby prevented or reduced.
- the contacting step further includes adding Ca ++ ions to the ECM.
- the method operates without adding Ca ++ under circumstances in which environmental Ca ++ is sufficient as calcium is the fifth most common element in earth’s crust, and the step of adding Ca ++ ions speeds up the resulting process of reducing porosity.
- the applying step includes adding Ca ++ ions to the surface after the contacting step, for example before or after curing.
- the Ca ++ is a solution of calcium formate.
- An aspect of the invention herein provides a cement alternative known as ECM having improved durability and corrosion-resistance, the cement mix comprising a carbonic anhydrase enzyme in an aqueous solution, the enzyme attached or embedded or enmeshed in a particulate admixture, the enzyme associated with at least one matrix selected from gelatin, agar or a hydrogel, or associated with at least one particulate material selected from silicone beads, silica gel, sand, grit, cellulose and cellulose derivatives, at a pH of 4.5-9.5.
- the corrosion-resistant cement mix in various alternative embodiments contains the enzyme at a concentration in a range selected from the group of 100 nM to 500 nM, 500 nM to 1 ⁇ M, 1 ⁇ M to 5 ⁇ M, and 5 ⁇ M to 10 ⁇ M.
- An embodiment of the cement mix further includes Ca ++ .
- compositions herein and methods of making and using these compositions provide concretes having corrosion resistance and durability and methods of repairing cracks in concrete. Additional examples are found in Matter 5: 1-18 published March 2, 2022, authors Wang, Shuai, Scarlata, Suzanne F. and Rahbar, Nima, and which is incorporated herein in its entirety by reference.
- Fig.1 is a schematic drawing illustrating the preparation and fabrication of enzymatic construction material (ECM), and the enzymatic healing process.
- Fig.2 is a graph showing the weight gain for four different material designs with constant CO 2 gas treatment with five bubbles per second rate. Adding a base increases the weight gain and the weight gain is the highest for ECa samples. In the box plot, the median value is illustrated as (-), the mean as ( ⁇ ), the values at 25% and 75% as box edges, and the values at 5% and 95% level as whiskers. The weight gain is observed to be due fixation of the CO 2 by the action of the carbonic anhydrase.
- Fig.3 is a set of microphotographs showing the scanning electron microscope (SEM) images and energy dispersive spectroscopy (EDS) maps comparing the effects of the CA enzyme, calcium source, and high pH as aqueous solutions additives on different samples.
- SEM scanning electron microscope
- EDS energy dispersive spectroscopy
- Fig.4A- Fig.4F is a set of microphotographs.
- Fig.4A and Fig. 4B show the dimension of a typical crystal bridge in the ‘non-gelatin’ sample, ECa, is smaller compared to a typical bridge in ECM. These data are evidence that gelatin can establish a proper scaffolding framework for crystal formation that further enhances and extends the size of the crystal bridges.
- Fig.4C and Fig.4D show that a typical crack initiates and grows in the calcite bridges bonding the sand particles.
- Fig.4E and Fig.4F show detachment of the sand particles from the matrix.
- Fig.5A is a photograph of a CA sand slurry sample prepared with #No.50 (the sand retained on a 300m sieve) white sand.
- Fig.5B is a photograph of the CA sand slurry sample after the uniaxial compression test.
- Fig.5C is a photograph of a CA sand slurry sample prepared with #No.30 coarse sand (retained on a 600m sieve).
- Fig.7 is a set of microphotographs showing optical (top row), and SEM (bottom row) images of the process of enzymatically catalyzed mineral precipitation and growth on the sand-gelatin system within the first 20 minutes of curing.
- Fig.9A and Fig.9B are a set of photographs of a single-edge notch ECM beam samples before the fracture test and after the fracture test respectively.
- Fig.13 is a set of graphs showing Fourier Transform Infrared Spectroscopy (FT-IR) analysis of the enzyme-produced Ca-carbonate and compared to a reference spectrum in which the sample precipitate had a dry weight of 0.4 ⁇ g, confirming the chemical composition of the repaired product resulting from the enzyme solution.
- Fig.14A is a photograph of a coarse sand slurry cube.
- Fig.14B is a graph showing the compressive strength of the coarse sand slurry cube with CA enzyme catalysis (Gelatin + Ca 2+ + CA) compared to intact control. The samples perform the highest average compressive strength 4.2 MPa.
- Fig.21A-Fig.21D are a set of Infrared thermal images of cured ECM-n thermal effect at different temperatures.
- Fig.21A shows that the laser heating experiment was set up at ambient temperature for ECM-n.
- Fig.21B shows the spatial view of the ECM-n at one-hour laser irradiation.
- Fig.21C shows he side view of the sample at one hour of laser irradiation.
- Fig.21D shows the process of laser heating of ECM-n at -20 °C freezer and the sample’s top surface temperature was raised to 60 °C in 10 minutes.
- Fig.22 is a graph showing the comparison of experiment and simulation of laser heating ECM-n. Temperature changes along the time and laser power for the ECM-n in 30 minutes.
- Fig.23A is a schematic illustration of the self-healing capability of the ECM-n beam via laser-induced heating. A trace amount of calcium-enzyme solution was added to the fractured area then ultra-pure CO 2 was aerated on the surface for 15 minutes.3W laser was conducted in the same location over 4 hours. The heterogeneous shape of the high- temperature region (white color) develops into a circle gradually.
- Fig. 23B shows ⁇ -CT scanned images of fracture and laser healing ECM-n beam at the front, center, and back layers.
- Fig.25A- Fig.25B show the compressive strength of laser-repaired ECM-n with different flaws ECM-n samples with different flaw shapes that were repaired and compared with oven-cured ECM.
- Fig.25A shows the laser repairing paradigm of ECM-n: The mean results are shown above each data set and a typical sample is shown at the bottom in Fig. 24B.
- Fig.26A-Fig.26C illustrate an Ashby diagram and scaling up ECM-n procedures Carbon footprint and mechanical properties of ECM/ECM-n compared to different construction materials.
- Fig.26A shows an Ashby diagram of embodied CO 2 versus embodied energy data.
- Fig.26B shows an Ashby diagram of specific strength versus embodied CO 2 for comparison with related construction materials.
- Fig.26C shows the procedures of fabricating ECM-n on the construction site.
- Fig.27 shows photographs of incandescent light curing of the ECM-n sample. The ECM-n sample was cured in 12 hours at the ambient condition.
- Fig.28A- Fig.28B show the comparison of mass loss and temperature over curing time between ECM n and ECM.
- Fig.28A shows the variation of the sample’s mass over time for ECM-n cured by 3W laser at room condition versus ECM.
- Fig.28B shows the temperature as a function of fully cured time at the center of 12.5 mm ECM-n sample surface under 3W laser induction compared with EICM without nanoparticles.
- the data were presented by a median with a sample size of 3.
- Fig.29A- Fig.29D show the thermomechanical modeling of ECM-n. The predicted three-dimensional temperature contour and the comparison of maximum temperature between experimental data and proposed prediction for ECM-n samples with different laser power. The heat transfer computation was carried out for three different powers.
- Fig.29A shows the FEM mesh of ECM-n.
- Fig.29B shows the Gaussian profile of order 1.
- Fig.29C and Fig. 29D show the 3D and top views of the ECM-n showing the temperature contour at 20 minutes with a 3 W laser illumination.
- Fig.30A-Fig.30B show the comparison of the self-healed ECM-n samples under the presence of carbonic anhydrase.
- Fig.30A shows that fracture sample was healed by calcium solution and CO 2 without enzyme.
- Fig.30B shows that the fracture sample was healed by calcium solution and CO 2 with the enzyme.
- Fig.31 shows the normalized Raman spectra of four different spots on the cured ECM-n surface. The peak analysis was processed and plotted by fitting the Gaussian function.
- Fig.32 shows a powder X-ray diffraction (pXRD) analysis of the enzyme-generated calcium carbonate in presence of laser induction, with a comparison to the reference spectrum for calcite. This comparison confirms the crystallinity of the product after laser curing resulting from the enzyme repair method.
- Fig.33 is a picture of a concrete slab that is 3 inches long and 3 inches wide having a fully repaired notch of 45mm x 4mm x 17mm. The concrete slab was placed between two stands such that the notch was suspended.
- Fig.34A- Fig.34B are a set of pictures of a concrete slab that is 7 inches long and 4 inches wide having a fully repaired notch of 60mm x 5mm x 40 mm.
- Fig, 34A shows that the length of the notch measured by a Vernier Caliper is about 56.4 mm. The concrete slab was placed between two stands such that the notch was suspended as depicted in Fig.34B.
- a gelatinous carbonic anhydrase enzyme was applied to the notch, the notch was air-dried, and the solution was reapplied to the notch. The process of applying the solution and airdrying was repeated for five days. The notch was observed to be fully repaired in 14 days.
- a negative emission Enzymatic Construction Material (ECM) with self-healing capabilities can be used as an alternative to concrete and Portland cement.
- the disclosed approach employs carbonic anhydrase (CA) to catalyze the covalent condensation of carbon dioxide and water or the fixing of carbon dioxide from the atmosphere, to promote the precipitation of calcium ions in an aqueous solution as calcium carbonate crystals.
- CA carbonic anhydrase
- Configurations herein depict a carbon-negative self-healing construction material compound, including a quantity of aggregates such as sand and gravel, a catalyst such as an enzyme, a scaffolding material having a crosslinking agent, and a calcium source.
- the mixture including the enzyme is configured to bridge sand particles in the quantity of aggregates for forming a dense, solid mass.
- This enzyme-driven method to bridge the sand particles results in a dense, stiff, strong, and tough structural material, which upon exposure to calcium source and CO 2 can also heal itself repeatably.
- catalyst and enzyme are interchangeably used.
- Production of ECM adsorbs CO 2 , hence not only it can reduce the current 9% global CO 2 emission caused by concrete production and repair, but it can also be used for carbon sequestration.
- the material is environmentally friendly, odorless, and harmless to humans and other organisms, with the highest mechanical strength ( ⁇ 12 MPa) reported for an alternative construction material. Additionally, the curing process of ECM (a few days at ambient temperature) is significantly faster than traditional concrete at 28 days.
- an aspect of the invention described herein provides a self-healing construction material compound, the compound including: an aggregate matter; a catalyst such as an enzyme; a scaffolding material; and a calcium source.
- the compound is a carbon-negative compound.
- the aggregate matter further includes sand aggregates.
- the scaffolding material further includes a crosslinking agent selected from glutaraldehyde, and tannin.
- the scaffolding material includes a polymer.
- the scaffolding material is gelatin.
- the catalyst is an enzyme such as carbonic anhydrase or a chemical analog of carbonic anhydrase or a synthetically manufactured carbonic anhydrase.
- An embodiment of the compound further includes a source of carbon dioxide.
- the compound sequesters atmospheric carbon dioxide.
- the compound has a mechanical strength from at least 10MPa to at least 16 MPa.
- An embodiment of the compound further includes at least one of: a light source, a heat source, a laser source, and a magnetic field application source.
- the compound is configured to form mineral bridges between the aggregate matter to obtain a dense mass.
- the calcium carbonate crystals are deposited on the aggregate matter to create mineral bridges.
- An embodiment of the method further includes dehydrating the construction material for facilitating crosslinking between scaffolding material.
- the calcium solution is configured to facilitate continuous precipitation of the calcium carbonate crystals.
- An aspect of the invention described herein provides a carbon-negative self-healing construction material compound, the compound including: a quantity of sand aggregates; a quantity of carbonic anhydrase catalyst; a gelatin scaffolding material; a calcium solution; and a quantity of iron oxide nanoparticles.
- An embodiment of the compound further includes a laser source or a light source for curing the compound. Most of the infrastructure is made of concrete.
- ECM is an alternative to cement that bridges the sand particles using a light and inexpensive polymer backbone through the deposition of calcium carbonate crystals, resulting in a hard, solid material that is twice as strong as the cementitious substrate and self-heals upon repeated large-scale cracking by incorporating an enzymatic catalyst.
- cementitious materials or other current building materials do not have a similar capability.
- the state-of-the-art in active building material is living building material (LBM), which uses photosynthetic cyanobacterium to precipitate calcium carbonate crystals or fungi. LBM fabrication is inefficient because the cost of bacteria is much higher than ECM and the process cannot be not easily operated in large-scale manufacturing.
- the structures, properties, and tissue distribution of the different CA isoenzymes are different; however, the isoenzymes have the same critical physiological functions in cell respiration by reacting CO 2 with water to yield carbonic acid in the body tissue and reversing the reaction in the lungs to generate CO 2 .
- the sequestration of CO 2 is based on the chemical fixation of carbonate minerals such as calcite, aragonite, and magnesite.
- the inventions described herein use a biomimetic CO 2 absorption mechanism using biocatalysts such as CA to reduce local CO 2 concentrations emitted from the production of cement.
- microbially-induced calcium carbonate precipitation includes applying Synechococcus from photosynthetic cyanobacterium in MICP, to develop long-term viability building materials (LBMs), which present a successive regenerated ability and is an alternative to concrete cement material.
- LBMs are not comparable to natural concrete cement, and this material is far from practical construction applications. Additionally, the mechanism of crystal precipitation and growth within the bio-scaffold is not efficient thereby resulting in a material with low density. The bacteria may require maintenance to continue viability.
- the examples described herein present a faster and more effective way to create a negative emission self-healing construction material using sand aggregates, a trace amount of enzyme, a small dosage of scaffolding material with a crosslinking agent, and a calcium source. Curing of the material can be performed at a high temperature for a short period or at room temperature for a longer period.
- This enzyme-driven method to bridge the sand particles results in a dense, stiff, strong, and relatively tough structural material, which upon exposure to calcium source and CO 2 can also heal itself repeatably.
- Carbonic anhydrase (CA) the enzyme used to generate the new material, can be easily stored and is stable at pH 6.5 - 8.5 and temperature of 30 – 50 oC.
- the reaction conditions generate an environment that promotes enzyme stability, consumes CO 2 , and avoids unhealthy reagents and pollutants.
- the mechanism of crystal growth on the scaffold yields outstanding mechanical properties and self-healing ability due to the catalyzing effect of CA.
- the enzyme-catalyzed process, structure fabrication process and 2D microstructure of the material, called enzyme construction material, ECM are shown schematically in Fig.1.
- Enzymatic construction material is a low-cost and environment-friendly construction material that possesses superior mechanical properties to concrete through enzyme-catalyzed crystal precipitation.
- the examples described herein show carbonic anhydrase (CA), an enzyme derived from biological cells, to facilitate the carbonation reaction by converting carbon dioxide to precipitate calcium carbonate crystals.
- CA carbonic anhydrase
- a synthetic analog of CA is used as the catalyst or enzyme.
- a polymer backbone (gelatin) provides a scaffolding framework for crystals to form and establish strong crystal bridges to connect the sand particles. The presence of enzyme molecules as catalysts allows ECM to possess self-healing capability.
- ECM is a viable alternative to concrete, as the most used material in the world.
- ECM has limitless possibilities for green construction materials and the creation of space construction materials.
- the examples described herein introduce a new paradigm in developing a negative- emission construction material with self-healing capability using sand, calcium, gelatin, and trace amount of carbonic anhydrase enzyme, named Enzymatic Construction Material or ECM.
- ECM possesses exceptional mechanical properties as a construction material with compressive strength (12 MPa) higher than any other available method and is twice as high as cement mortar. Therefore, ECM can be used to repair or even replace Portland cement concrete.
- the examples described herein examined the influence of CA enzyme catalysis, high pH condition, and gelatin on the overall strengthening and toughening mechanism in the ECM.
- the data show that wider and longer mineral bridges are incorporated in the microstructure of ECM compared to samples not containing enzyme and/or base samples. The bridges strengthen and toughen the material.
- the self-healing capability of ECM was investigated through a cyclic fracture routine and healing examples, in which the ECM samples withstood up to six cycles of fracture. Therefore, the enzymatic mineralization method is useful to create a negative emission construction material and a method of carbon sequestration.
- the ECM can be rapidly manufactured with an environmentally friendly procedure, and therefore is a substitute for current building materials.
- the ECM requires only a small amount of low-cost polymer as a scaffold and incorporates only trace amounts of an enzyme to produce an odorless, inexpensive, environmentally friendly, and mechanically strong material.
- the ECM can heal itself after multiple damage cycles at the same location demonstrating strong self-healing capacity.
- the ECM is cured by baking at low temperatures.
- the ECM is cured by light.
- the ECM is cured by applying a magnetic field.
- ECM is a negative emission structural material with the self-healing capability which further enhances its durability, and consequently, its negative carbon footprint. The material can be essentially used as an alternative carbon sequestration method.
- ECM alleviates the high monetary and energy costs associated with the production and use of concrete and consumes the greenhouse gas carbon dioxide. Most important, ECM does not use any harmful reagents with foul odors that would limit the application of the final structure. Therefore, ECM provides a novel, low-cost, safe, and highly efficient way to create a sand slurry material with a strong self-healing capability. ECM is a new material and method for the development of environmentally friendly construction materials. Therefore, Enzymatic Self-Healing Construction Material is negative emission material that consumes CO 2 during production, and during its self-healing process. Traditional concrete curing requires an adequate amount of moisture for continued hydration and 28 days to achieve mechanical strength.
- Embodiments of the invention described herein show that adding a trace amount of iron oxide nanoparticles to ECM generates an improved material called ECM-n that is cured with a low-power laser, or incandescent light (Fig.27).
- This method based on studies of laser-induced nanoparticle application in hyperthermia therapy utilizes the exothermic behavior of iron oxide nanoparticles under external electromagnetic (radiofrequency, microwave, and laser) excitation.
- Example 1 Enzymatic solution preparation
- CA analytical grade carbonic anhydrase
- THAM tris (hydroxymethyl) aminomethane
- Example 2 Calcium carbonate solution preparation To prepare a buffer solution, 0.1M tris (ordered from Sigma Aldrich) was added to 200 mL deionized water, mixed with 2M saturated solution, and stirred for two minutes. Calcium chloride dihydrate was chosen as the calcium source because it can generate calcium carbonate more efficiently. A high concentration of free calcium ions in the solution expedites the dissolution of calcium chloride dihydrate. When the calcium chloride dihydrate was dissolved substantially, 10L of 100M CA solution was added into a 1000 mL beaker and stirred for another two minutes. CO 2 gas was then introduced into the solution at a rate of five bubbles per second for 10 minutes. A pH meter was used to record the entire process. Some fog was observed to be produced from the solution after five minutes.
- 0.1M tris ordered from Sigma Aldrich
- Example 3 Cubic and cuboid ECM sample fabrication Cubic samples 25 mm were prepared for uniaxial compressive tests. A loading rate of 1.27 mm/s was chosen. Single-edge notch beam samples were prepared for the fracture test and plain beam for the bending test.10% gelatin by weight (gelatin/solution) was mixed with sand for two minutes. Gelatin was chosen because of its chemical compatibility with CA, and because the completely soluble temperature of gelatin is 35 oC, which is within the temperature range of carbonic anhydrase activity.
- Example 4 Weight gain Four groups of solutions were prepared (Ca: Ca 2+ ; BCa: Base + Ca 2+ ; BEC: Base + CA +Ca 2+ ; ECa: CA + Ca 2+ ) similar to the method described in Enzymatic solution preparation. The solution was then aerated with CO 2 gas (5 bubbles per second) for 10 minutes with continuous stirring. The weight of the solution was measured immediately after the end of the experiment.
- Example 5 Self-healing experiment procedure To examine the self-healing capability of ECM, single-edge notch beam samples were prepared similar to the method presented in the Cubic and cuboid samples fabrication process section. The first cycle was initiated with the beam samples that were fractured under three- point bend test and then placed back into the silicon mold. To demonstrate the self-healing process, a constant amount of 2 mL of calcium-enzyme solution was titrated evenly on the surface of the crack region. Then CO 2 gas was aerated through a rubber tube with constant pressure on the crack surface for 10 minutes. Samples were then desiccated in the 100 oC oven for 24 hours and then underwent the three-point bending fracture test.
- Example 6 Glutaraldehyde modification Glutaraldehyde 50% concentration was acquired from TCI AMERICA company as the ECM crosslinking agent. Gelatin and glutaraldehyde at a 1:1 ratio were then added by weight on the surface of the ECM samples. The samples were placed at room temperature for half an hour until the gelatin/glutaraldehyde solution completely penetrated the sample. The samples were then desiccated for another 24 hours and then mechanically tested.
- Example 7 X-ray diffraction (XRD) and FT-IR analysis Analysis of the dried enzyme solution product was conducted by powder X-ray diffraction (pXRD) and Fourier Transform Infrared Spectroscopy (FT-IR) to confirm both the chemical composition and crystallinity.
- XRD X-ray diffraction
- FT-IR Fourier Transform Infrared Spectroscopy
- pXRD was performed on a Bruker AXS D8 Focus (Bruker, Billerica, MA, 102 of 190 USA) at 25°C, and the pXRD spectrum used a CuKa radiation source at 40 keV and 40 mA from 20° to 90° of 2 ⁇ with a step size of 0.100°, against the baseline and FT-IR was carried out on a Bruker Optics Vertex 70 equipped with a Specac Golden Gate Diamond Single Reflection ATR element (Bruker, Billerica, MA, USA). The calcium carbonate prepared from the enzyme solution was rinsed and dried for analysis.
- Fig.12 compares the pXRD spectrum against the reference spectrum for calcite
- Fig.13 compares the FT-IR spectrum of the dried enzyme product against the baseline FT-IR spectrum for Ca-carbonate obtained from the RUFF Project database. Both results verify the chemical composition and crystallinity of the enzyme product as calcite.
- Example 8 Compressive strength of cubic coarse sand ECM The uniaxial compressive experiments were performed following the American Society for Testing and Materials (ASTM) standards on ECM specimen with coarse sand (NO.30, the sand retained on a 600 ⁇ m sieve as alternative sand mixing in the materials), since ECM design possessed the highest compressive strength compared to intact and high pH specimens in the extensive fine sand experimental plan.
- ASTM American Society for Testing and Materials
- Example 9 Fracture and bending test The results of the three-point fracture experiments are presented in Fig.15A- Fig. 15C. The fracture experiments were followed using the method in ASTM standard. A cured silicone mold with a sharp crack was prepared and used for sample preparation. A four-part solution of 10ml CA enzyme, tris base, 2M Calcium chloride dihydrate and DI water was prepared. It was then thoroughly mixed for two minutes and bubbling CO 2 gas for 10 minutes.
- Example 10 Crystal bridge growth mode
- the gelatin scaffold provides a stable platform for crystal nucleation and growth.
- the solute calcium carbonate then continues to precipitate around bridges which causes the surrounding concentration of calcium carbonate lower than the entire system.
- the solute CaCO 3 precipitate at the gelatin surface is denoted as CR.
- the molar concentration of crystals in the solid mineral is represented by Cr.
- the molar concentration of CaCO 3 in the solution right around the solid mineral is C 0 , which is very low.
- the dissolution of calcium carbonate is difficult since its solubility is only 13 milligrams per liter.
- the concentration profile is shown in Fig.17A. Three defined concentrations follow a relationship written as C r > C R ⁇ C 0 .
- Example 12 Catalytic performance CA is the fastest known enzyme with a high rate of catalysis of CO 2 in a diffusion- controlled process.
- the method of creating ECM is based on CA catalyzing the rapid precipitation of CaCO 3 to create mineral bridges that connect the sand aggregates in two separate steps: CA first catalyzes the reversible hydration of carbon dioxide to bicarbonate (Equation 13) which then reacts with calcium ions in the solution to precipitate CaCO3 (Equation 14).
- Equation 13 the reversible hydration of carbon dioxide to bicarbonate
- CaCO3 Equation 14
- Synthetic CA analogs mimic the CA reaction. However, the synthetic analogs may be less efficient and would have to be used at higher concentrations to achieve similar results. The efficiency of the reactions depends on four key factors: (1) the concentration of calcium available for the nucleation site.
- the catalysis by the CA enzyme shows a high biomineralization efficiency where the calcite crystals (CaCO3) self-assemble into a sand- gelatin matrix to establish ‘bridges’ between the sand particles.
- Gelatin serves here as a harmless and odorless scaffold, which gains strength by physical crosslinking after dehydration. It can be regarded as a carrier of crystal, connecting the whole microstructure system.
- (13) (14) There is enough ambient carbon dioxide in the air to drive the main chemical reaction prescribed earlier. While the reaction between carbon dioxide and water is reversible, both sides of the reaction proceed simultaneously to achieve a “dynamic equilibrium”, which hinders the precipitation of the calcium carbonate crystals.
- the buffer solution is composed of the weak acid “HA”, and its own salt “NaA”.
- the buffer solution contains enough alkali “A-” ions used to buffer the strong acid in the solution.
- A- alkali
- H + ions are consumed by “A-” ions, and the pH value of the solution is constant.
- the calcium carbonate crystals can precipitate successfully.
- the efficiency of CA was quantified by measuring the weight gain from the precipitated crystals produced in the enzymatic reaction. The results of weight gain from four different solutions are presented in Fig.2.
- ‘Ca’ represents the aqueous solution that includes only the calcium source
- ‘BCa’ represents the base and calcium source solution
- ‘BEC’ represents the base, CA enzyme and calcium source solution
- ‘ECa’ represents the system of the sand slurry without gelatin, in which only CA enzyme and calcium source were added into the solution.
- the weight gain is not equal to the amount of precipitated crystal precipitation but indirectly reflects the catalytic ability of the enzyme to convert carbon dioxide.
- the weight gain in every solution is equal to the quantity of absorbed CO 2 , which is used to calculate the weight of precipitated calcium carbonate based on Equations 13 and 14.
- Table 1 A comparison of the CA enzyme catalyze activity in experiment and theory The theoretical and experimental results are compared in Table 1.
- the theoretic result for CO 2 molecules is 3.49* 10 23 and the experimental molecules quantity of CO 2 molecules is 1.12*10 22 , considering the experimental error and the effect of carbon dioxide on pH (K cat will change by pH), the experimental results are well in agreement with the predicted results in the ambient temperature regime, and the enzyme indeed performed an improvement in carbonation. Comparing the BCa samples in Fig.2 with Ca samples, it was observed that more crystals precipitated after adding a base reagent to the solution. From Equation 13, the hydroxide ions neutralize the hydrogen ions in the solution and push the reaction forward.
- the urease uses the nitrogen source, urea, to produce hydroxide ions to increase the solution pH, causing calcium carbonate to precipitate from the calcium ions in the solution.
- Example 13 Microstructural Characterization To understand if the composition and morphology of ECM are influenced by the presence of the CA enzyme, four different compositions were used to assess the quantity of mineral precipitation, mineral distribution, structural arrangement, and bridge size different at high pH, no CA enzyme and no calcium source.
- the control ‘GL’ (Gelatin) samples were created with the same media as the ECM (CA + Gelatin + Ca 2+ ), but only containing gelatin.
- the ‘BGE’ Base + gelatin + CA + Ca 2+ ) represents a high pH control group, where higher pH helps to produce more partials of calcium carbonate.
- the ‘GCa’ (Gelatin + Ca 2+ ) samples demonstrate the effectiveness of the CA enzyme in crystal precipitation and microstructure of the resulting product which was fabricated with the gelatin and calcium source. Compared to the other three groups, it was observed that the structure of ECM is denser and more organized. The surfaces of GL and GCa samples were found to be smooth, and their bridges in some domains were too short or too fine. The mineral bridges in BGE are stronger, but the overall arrangement of structure is inordinate. During the preparation of ECM, most of the calcium carbonate crystals were trapped or covered in the gelatin and formed a bridge, and it is difficult to observe the crystal distribution of the surface directly through SEM.
- EDS Energy Dispersive X-Ray Spectroscopy
- the size of the ECa bridge (around 80m) is smaller than the ECM (150m), which means that the gelatin scaffolding enhances and extends the bridges.
- the crystals align closely in gelatin resulting in an organized and dense structure that establishes a mechanism for the enhancement of the mechanical properties of the ECM and provide the physical basis for increased durability and corrosion resistance of the resulting product.
- the fracture mechanism of ECM relies on the bridging connections among the sand aggregate components.
- Fig.4C and Fig.4D show the ECM sample after mechanical testing, displaying the cracks that propagate in the center of the bridges in the transverse direction.
- the compressive strength and elastic moduli are presented in Fig.5A- Fig.5E.
- the main function of construction materials such as concrete is compressive strength.
- the compressive strength of the concrete mixture depends on the properties of the aggregate and cement mortar matrix.
- ECM also possesses its own ‘aggregate’ and ‘mortar matrix’, and its mechanical properties are similarly a function of the strength of sand and mineral bridge.
- the results in Fig.5A show that gelatin as scaffold in GCa can increase the compressive strength of the sand slurry material ECa. However, in comparing GCa with ECM, an average strength of 4.5 MPa is not noticeable.
- the data show that the ECM performs with the highest compressive strength and elastic modulus.
- the average compressive strength of the ECM samples is 9 MPa, which is twice as high as the GCa specimens, 4.7 times greater than the ECa specimens, and significantly higher than the base amended specimens of BGC & BGE (Fig.5D).
- the elastic modulus of ECM is higher than other specimens, which means the elastic deformation under the same external force is smaller. It can be observed from EDS-SEM images in Fig.3 that the size of crystal bridges in the ECM on average is about 150 m wide and 50 m long. Also, the calcium carbonate crystals in ECM are distributed more uniformly. Comparing the EDX maps of ECM samples with BGE and BGC samples, a significant amount of calcium was observed on the ECM bridges.
- the crystal bridges are the principal strengthening and toughening mechanisms in these heterogeneous materials.
- the compressive strength of ECM is more than two times of standard cement mortar (with a specific strength of 3.5 MPa).
- the sand slurry cubic samples with coarse aggregates were also fabricated (Fig.5C), and their compressive strength is presented in Fig.14.
- the coarse sand slurry ECM performs a higher average strength than high pH BGE samples by about 31%, and control gelatin samples GCa by about 17%.
- CA enzymes play the same role in both fine and coarse sand samples by increasing the rate of crystal precipitation within a fixed time, and consequently, strengthening the samples.
- Example 15 Tensile test Fracture energy is an important mechanical property of building materials since the propagation and control of cracks are highly related to the serviceability and durability of materials.
- the average ultimate load of ECM samples is also higher than GL samples by about 27% and GCa samples by about 16%.
- the fracture and bending tests of coarse sand slurry ECM are illustrated in Fig.15A-Fig.15C.
- the fracture energy of coarse sand slurry ECM is higher than control ‘GCa’ by about 38%, and higher than high pH samples (BGC) by about 120%.
- BGC high pH samples
- the interfacial fracture toughness between the crystal bridges and the sand surface which are a function of the surface roughness of the sand particles, can also affect the overall strength and toughness of these materials.
- previous publications state that a high pH condition can benefit the extent of carbonation, the overall performances of samples with the high pH preparation in the tests herein are not as good as the performances of the ECM samples.
- adding base reagents generates a portion of the calcium hydroxide with calcium carbonate in the precipitation.
- Calcium hydroxide consists of one calcium cation and two hydroxide anions at the molecular scale
- calcium carbonate consists of one calcium cation and one carbonate anion, in which both calcium hydroxide and calcium carbonate are non-polar.
- Example 16 Crystal growth modeling Understating the crystal nucleation and growth are of prime importance in determining and predicting the physical properties of ECM. Hence, optical and electron microscopy were extensively utilized to study the time-lapse of crystal growth in ECM samples.
- Fig.7 the formation of calcium carbonate crystals on the sand-gelatin system surfaces is analyzed using SEM and optical images.
- ECM the rough surface of the gelatin scaffold and sand provides numerous sites for the nucleation reaction of calcium carbonate in solution.
- the crystal growth method is defined by heterogeneous nucleation, thus, the energetic barrier problems associated with preliminary nucleation are inevitable.
- carbonic anhydrase reduces the activation energy for the reaction barrier. It is observed from the images that the calcium carbonate crystals are formed immediately under enzymatic catalysis. Crystal growth then results in the gradual expansion of the cross-sectional area of the bridges and the formation of the bridging network between sand particles.
- Example 17 Self-healing Properties
- the fracture strength of the beam specimens in each cycle was measured to evaluate the extent of healing in the ECM.
- the fractured samples were placed in a silicon mold and treated with a trace amount of enzyme + calcium solution on the crack surface region (Fig.9A and Fig.9B).
- the healing structural materials with a significantly large defect require the addition of some filling materials which is also required in all other self-healing methods such as MICP and Living Building Materials (LBM)s.
- the carbon dioxide in the air can be involved in the self-healing reaction; thus, this process also plays a small role in carbon dioxide sequestration during healing.
- the results in Fig.9F show that the average maximum load is decreasing from the second healing cycle with a relatively stable decline up to the fourth cycle. From the fourth cycle of healing, the average maximum load plateaus to about 23 N, which is half of the intact property.
- Example 18 Reinforced ECM
- crosslinking agents such as glutaraldehyde, genipin, and microbial transglutaminase are applied.
- glutaraldehyde was chosen as the ECM crosslinking agent which is by far the most widely used with gelatin, due to its accessibility, low cost, and high efficiency of collagenous material stabilization. Only a very low concentration of glutaraldehyde (1% by gelatin weight) is sufficient to obtain a 100% degree of crosslinking and a 20 times increase in Young’s modulus concerning the uncross linked gelatin film.
- the crosslinking of gelatin with glutaraldehyde involves the reaction of the free amide groups of the lysine or hydroxylysine amino acid residues in the polypeptide chain with the aldehyde group of glutaraldehyde. As the degree of crosslinking increases, the thermal and mechanical properties of gelatin are also increased. Tannin is used as an additive to improve the mechanical, thermal, and moisture absorption behavior of gelatin-based adhesives. It was shown that the bond strength (tensile) was increased when tannin is added by 16%. The compressive strength of the results of glutaraldehyde was compared to Tannin in ECM.
- Fig.11 displays the compressive strength of glutaraldehyde- modified ECM at around 11.5 MPa, which is 28% higher than the ECM. Meanwhile, tannin modification (27% by gelatin weight) of ECM samples failed to reinforce the ECM structure. Although glutaraldehyde is an irritant, thousands of successful bio-prosthetic implants have demonstrated that glutaraldehyde cross-linking is clinically acceptable, having reduced cytotoxicity at very low concentrations.
- Example 19 Laser-induced Curing of ECM-n To verify the effect of nanoparticles on ECM curing rate, the 12.5 mm cubic ECM-n (ECM with 0.1% iron oxide nanoparticles) and ECM were fabricated using the same method and subjected to the same power laser.
- Example 20 Heat Released Analysis During the Initial Curing
- ITC Isothermal Calorimetry
- Example 21 Laser Heating ECM-n In Low and Room Temperatures
- Fig.21A and Fig.21C demonstrate the photothermal effect on cured ECM-n at ambient temperature induced by a 3W continuous wave laser.
- Fig.21A shows the experimental setup.
- Fig.21B and Fig.21C show the top and side views of the contours of temperature for an ECM-n sample subjected to laser heating for about one hour, respectively.
- the peak temperature is concentrated in the center of the sample surface and spreads radially outwards into the surrounding surface region.
- the influence of heat convection on the side can be observed in Fig.3C.
- the temperature profile shows a curve in the form of layers, with the lowest temperature at the furthest position from the heat source.
- the photothermal effect of cured ECM-n was also explored at low temperatures.
- the time sequence of the experiment is presented in Fig.21D.
- the sample was stored in a -20 °C freezer to obtain a homogenous temperature on the surface.
- the schematic on the left shows the experimental setup.
- Example 22 Thermal Modeling of Laser Heating
- FEM Finite Element Method
- COMSOL Multiphysics 6.5 COMP, Inc. Burlington, MA
- a thermal conductivity parameter was used to represent the iron oxide in this ECM-n model for two reasons: 1) During the dehydration process, the gelatin undergoes a phase change from a gel to a crystalline state, which complicates the modeling process; 2) the iron oxide possesses a higher thermal conductivity than sand and gelatin, which significantly affect the temperature of the system.
- the absorption coefficient, ⁇ depends on the object material and the interaction between the object material and the wavelength (808) of the laser, where most models use a constant absorption coefficient by neglecting the influence of incident angle and temperature. To simplify, the absorption coefficient was assumed to be 1, and Q (W/G3) is the laser heat source term.
- Equation (15) at the side of ECM-n are heat transfer by convection, and at the top surface is radiation.
- the convection (Newton’s law of cooling) in the laser heating process is expressed by (16)
- the radiant heat flow rate of the object can be computed based on the empirical formula of Boltzmann’s law by (17)
- Heat convection always is transferred by gas or liquid media.
- the air is the major media in the convection, for simplicity, the heat convection coefficient is considered to be uniformly distributed, and equal for all surfaces of the boundary, where, h, the natural air heat convection coefficient is 25 W/m2 ⁇ k.
- ⁇ the emissivity of sand is estimated to be 0.95.[19] ⁇ is the Stefan-Boltzmann constant, and is the direction vector. Text and Tamb are the medium air and room temperatures, respectively, where both are assumed to be 300 K.
- the rate of heat generation by the Gaussian profile of a transverse model optical intensity of order n can be given by (18)
- the laser power intensity (W/G2) can be expressed by (19) and the Gaussian laser term is (20) where the laser beam was defocused to a processing radius of 6 mm.
- the Gaussian laser intensity profile of order 1 was implemented in Fig.29B.
- the scaffold bridges are exposed on the fracture faces, which implies that the mineral bridges are the weak link in the microstructure of ECM.
- the fractured sample was assembled in a silicon mold and then the CO 2 gas was sprayed continuously on the fracture region. In the healing process, the precipitated CaCO 3 crystals were expected to gradually grow on the scaffold, and eventually bridge the fracture interface during laser heating. It was noted that the additional carbonic anhydrase was added with the calcium solution in the crack area, this is due to the decreasing enzyme activity during laser photo illumination.
- the fracture cuboid ECM-n sample was treated with calcium solution with a trace amount of enzyme (5 ⁇ L, 2.9 mg/mL) compared with the sample without enzyme treatment in the calcium source agent, which presented more crystals on the repaired crack after laser curing (Fig.30A-Fig.30B).
- a trace amount of enzyme 5 ⁇ L, 2.9 mg/mL
- the macroscale characterizations of the self-healing process can also be observed from the temperature profile of the sample. The temperature profile contour changes during the healing process, as expected because the nanoparticles are carried by a fluid medium and diffused until the sample is desiccated.
- the 4.1 mm x 3.5 mm fracture surfaces were fully repaired after four hours of laser treatment.
- the resulting ECM-n has the same self-healing capability as ECM and provides a potential application for outstanding material durability.
- ⁇ -CT scanning images clearly show the crack path disappearing in three display layers (front, center, and back), indicating that the internal crack has self-healed as predicted by laser photo illumination.
- the overall view is similar to a body centered cubic (BCC) crystal.
- BCC body centered cubic
- the sand particles in both samples are connected with bridges in at least four directions. Due to the characterization of the BCC structural type, sand slurry materials show a high ductility during the bending test, and with a high strain at 0.0032 compared with a normal weight concrete in the range from 0.002 to 0.003. As a result, the local application of the photothermal effect by iron oxide nanoparticles exhibits a mild effect in ECM-n, showing the high extent of stability and mechanical strength in sand slurry materials structure.
- the nanoparticle distribution in ECM-n was also investigated by Energy Dispersion Spectroscopy (EDS), optical microscopy, and Raman spectroscopy, as shown in Fig.24B, Fig.24H, and Fig. 31, respectively.
- EDS and optical images clearly show the nanoparticles distributed on each of the sand particles, correlating to a spherical temperature profile.
- the slight aggregation of nanoparticles occurring on the surface is due to the lack of surfactants during nanoparticle preparation.
- the surfactant coating consists of a variety of ester-based materials that depend on environmental factors at varying levels of chemical complexity, thus, only physical treatment was applied to the nanoparticles by the ultrasonic method to avoid a negative impact on the medium.
- Raman spectroscopy is a nondestructive analytical technique based on changes in the scattering of low-energy light off material and can be used directly on the whole sample.
- Fig.31 displays the locations on the ECM-n surface that correspond to calcite and gamma Fe2O3. The spectra were processed and plotted proportionally by fitting the Gaussian function.
- the Raman characteristic peak of calcium carbonate is relatively narrow, indicating a high extent of crystallization, and the intensity of the peak is higher, indicating a higher content of calcite crystals and iron oxide nanoparticles in this region of the sample surface.
- the ECM-n samples with a vertically oriented elliptical flaw that is 6 mm tall and 1.5 mm wide and extends through the cubic sample through the entire 12.5 mm depth representing a macroscale crack exhibit about 74% of the strength of the undamaged control specimens.
- the compressive strength results show that cube-shaped samples with built-in flaws can regain their original compressive strength by adding the calcium enzyme mixed solution to the original sand gelatin matrix. The material was then bubbled with ultra-pure carbon dioxide for ten minutes. This is followed by the application of the laser for curing for 12 hours.
- the samples with large sizes of the repaired flaws exhibit the capability of the proposed method in the repair of the ECM specimens. It is noted that both repaired flaw shape samples slightly outperform the control samples concerning the average compressive strength. The compatibility of the existing matrix with the additional sand-gelatin repair agent is excellent, and the repair process also allows additional curing of the original matrix, leading to an overall stiffer structure. Comparing the results, the variation in the strength of the elliptical flaw and repaired elliptical flaw ECM-n samples is relatively high. This difference is mainly due to the geometric offset of the elliptical flaw during the sample preparation in the silicone mold.
- Example 26 Embodied Energy and CO 2 of ECM/ECM-n To visualize the impact of ECM/ECM-n on sustainable environmental protection and various types of construction materials, the embodied energy vs. embodied CO 2 and specific strength vs.
- the enzyme, carbonic anhydrase, which is added in trace amounts, is isolated from bovine erythrocytes or other natural sources, which does not generate carbon dioxide, and requires little energy.
- the calcium can be obtained from natural brines as a by-product of synthetic soda ash production.
- Another low-carbon method is to produce calcium from hydrochloric acid and limestone. The process will generate hydrogen that can be directly burned or generated by fuel cells to obtain water, which can be achieved by true zero carbon emissions without polluting the environment.
- the gelatin is extracted by hydrolysis of biological material in a process that is essentially zero-emission.
- ECM-n is proportional to the number of nanoparticles and the power of the laser. Therefore, in on-site construction, a higher number of nanoparticles and higher power of laser are suggested to apply on the ECM-n to guarantee the desired effects. For example: to fabricate a 10 ft X 10 ft ECM-n slab, precured ECM-n can be prepared on the foundation, and then ten industrial laser machines can be induced at different spots (assuming the effective area is 0.5 ft X 0.5 ft).
- Example 27 Laser-induced curing of ECM-n
- the laser diode corresponds to a heating power of 3W.
- the laser beam was transmitted through a fiber optic cable to the tip of a cylindrical probe before propagating into the sample.
- the distance between the tip of the probe and the sample surface was set at 2 cm to achieve a laser spot size of 1 cm on the samples.
- Example 28 Laser-induced self-healing of cuboid samples The single-edge notch cuboid sample was fractured into two parts.
- Example 30 Mineralogical assessment of precipitates The crystal and nanoparticles in ECM-n samples were segregated from the gelatin and sand matrix for assessment of the mineral phase in ECM-n after laser inducing for twelve hours. Dried crystals and nanoparticle mixtures were ground with the mortar and smear- mounted on a sample holder for fingerprint XRD. A Siemens D500 X-ray diffractometer analyzed the samples from 70° 2 ⁇ using Cu K- ⁇ X-ray radiation with a step size of 0.02° and a dwell time of 2s per step. Mineral phases were collected using a data collector. The laser- cured ECM-n was evaluated using JEOL JSM-7000F Analytical SEM. Samples were first sputter coated with gold powder.
- Electron-dispersive spectroscopy was employed to assess the nanoparticle distribution in the ECM-n matrix.
- Example 32 Heat Released Analysis During the Initial Curing Isothermal Titration Calorimetry (ITC) can measure the thermal power (heat production rate) produced by the hydration reactions of cementitious materials.
- ITC Initial Curing Isothermal Titration Calorimetry
- ITC tracks the rate of the overall reaction of the material and visualizes the behavior of the hydration in a way that a simple set time or a compressive strength test does not.
- the timing and shape of the heat flow curve obtained by calorimetry indicate the relative performance of concrete and potential adverse interactions between materials used in the mixes.
- Example 33 Laser Heating ECM-n In Low and Room Temperatures All the physical and thermal properties of the ECM-n sample were extracted from experimental data to be used in the FEM. The geometry of the ECM-n was modeled with standard 8-node linear heat transfer elements in three dimensions, which is shown in Fig. 29A.
- ECM-n Morphology and Crystallinity Characterizations Raman spectroscopy can provide qualitative analysis of sample phases and morphology, crystallinity, and molecular interactions.
- the peak profiles are generally defined by three parameters: peak intensity, width, and position. The peak intensity is affected by object concentration and orientation.
- the peak width is related to crystallinity and homogeneity, and the peak position is associated with the components.
- the carbonate phase (calcite) and gamma Fe2O3 comprise major portions of the material and are relatively easily identified through a phase ( ⁇ 1086 cm-1) and Fe2O3 band ( ⁇ 225 cm-1) since both are strong Raman scatterers.
- Example 35 Method and Materials for Repair of Cracks and Fractures Cracks are assumed as stated above to be the initiating cause of concrete failure. Although very strong, concrete can be brittle and prone to fracture. Current repair methods are inadequate resulting in a weakened material.
- the invention described herein provides in one embodiment a method to repair large concrete surfaces using a gelatinous embedded enzyme, carbonic anhydrase, in a calcite solution.
- This enzyme is found universally in biological systems, for example in humans to regulate the pH of intracellular pools, and fixes carbon dioxide to produce carbonate, an environmentally useful reaction.
- the commonly used repair materials for concrete cracks mainly include epoxy systems and acrylic resins. which are all environmentally unfriendly, and often cause delamination or cracking between the original concrete matrix and the repair material. Cracks are the initiators of concrete failure.
- the present invention provides a method to rapidly repairs larger ( ⁇ 5mm) cracks in concrete. Repair of small cracks and fractures of small cement samples bathed in a carbonic anhydrase enzyme (CA) has been described (U.S. patent number 10,647,617 issued February 28, 2018).
- CA carbonic anhydrase enzyme
- CA repair solution In real world situations where the CA repair solution must be applied to a larger crack on a surface where immersion and deposition are not practical, the repair solution will flow through the material becoming dilute and not accelerating repair.
- a substrate such as a silicon bead
- a solvent that does not allow fast diffusive flow through the concrete such as hydrogel, or gelatin
- calcium nitrate is used as a safe and non-toxic corrosion inhibitor (Al- Amoudi, O. S. B. et al. Cement and Concrete Composites 2003, 25 (4), 439-449.).
- CA carbonic anhydrase
- the concrete surface is vertical, and the repair solution flows through the crack, or the repair solution flows through the material becoming dilute and does not repair.
- a carbonic anhydrase enzyme solution is combined with gelatin for use as a scaffold or the enzyme is incorporated into a substrate such as a silicone bead.
- the carbonic anhydrase enzyme is dissolved in an aqueous solvent and embedded in a matrix such as a hydrogel, agar, or semi-solid gelatin. Therefore, the enzyme solution when used to apply to a cementitious surface, rather than flow diffusively through the concrete, remains mixed into the cement thereby allowing the repair reaction to continue for the lifetime of the enzyme activity.
- the enzyme used Recombinant Bos taurus (bovine) CA-II expressed in Escherichia coli
- the enzyme was dissolved in 0.1M Tris buffer, 160 mM NaCl, pH 9.5, aliquoted and stored at ⁇ 20° C. until use.
- one or more carbonic anhydrase enzymes from any source would be appropriate, for example, obtained from bovine, porcine or ovine waste products such as blood or offal.
- Bacterial and yeast enzymes are likewise suitable, obtained from cellular mat material byproducts of high-value protein fermentations or other industrial sources.
- carbonic anhydrases obtained from a thermophilic species may be advantageous for use in cement repair in a tropical climate, and similarly from a xerophilic bacterium advantageous in a cold climate.
- Enzyme suitable to the methods herein need not be purified nor recombinantly produced, for example, crude cells extracts precipitated with ammonium sulfate to 60% to 65% saturation, or extracted with organic solvents and redissolved may be sufficient for large-scale industrial concrete use.
- Methods of purification of carbonic anhydrase are well known, see for example, da Costa et al., Chemosphere 88 (2012) 255-259.
- the recombinant bovine enzyme product was precipitated from a 49.6:49.6:0.74:0.0001 volume percent solution of four parts in a beaker on a stir plate: 200 mL of 2M calcium chloride dihydrate, 200 mL of 0.1M Tris base, ultrapure water, and a 5 ⁇ L aliquot of 20 mM bovine CA supplied in 150 mM sodium chloride.
- the amount of carbonate anhydrase enzyme (CA) used was very small, and being a catalyst is recycled through multiple rounds of production.
- the primary 50:50 percent solution of 2M CaCl 2 and 0.1M Tris base had an initial pH of 9.5.
- the pH was observed to have been reduced as a result of enzyme activity by 0.1 units upon the addition of bubbled CO 2 gas.
- the 5 ⁇ L aliquot of the CA solution was rinsed from its container with 3 mL of ultrapure water and added to the beaker.
- the CO 2 gas was continuously bubbled for 20 minutes and the pH of the solution was observed to have reduced from 9.5 to 7.4.
- the CA solution was left to stand for 24 hours and then the supernatant was removed.
- the CA solution was stirred well for two min and 20 mL of the solution was siphoned and heated to 35oC.
- Gelatin Knox, 1g
- the concrete slab was placed in two stands so that the notch was suspended. A volume of 10 mL of the CA solution with gelatin was filled in the notch evenly and the notch was entirely covered by the solution. The concrete slab and the notch were airdried for 24 hours. CA solution with gelatin 10 mL was again applied to the notch. After 24 hours of air drying, 7 mL of CA solution without gelatin was filled in the notch. The slab and the notch were allowed to air dry for 4 hours, and the notch was again filled with 7 mL of the CA solution without gelatin. The procedure of air-drying for 4 hours and reapplying the CA solution without gelatin was repeated for 5 days. The CA solution with gelatin maintained the seal and the CA solution without gelatin stayed in the notch.
- the reduced porosity of the resulting concrete extends the life of the concrete structures by blocking the access of harmful ions such as chloride.
- Chloride is deleterious to concrete, and is a major factor in concrete failure in coastal regions. Porosity is assayed by the physical analytical methods shown in Figures herein. In actual use during construction, porosity can be determined more quickly and conveniently on site also by use of visible dyes to assess reduced porosity and consequential increased corrosion resistance. Negatively charged dyes that mimic chloride ions in size and charge are preferably used. Coomassie Blue or brilliant blue which has a negative charge at neutral pH is an exemplary dye for this purpose. See also Savicheva, E. et al. Angewandt. Chem. Int. Ed.
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| PCT/US2023/013183 WO2023158717A1 (en) | 2022-02-17 | 2023-02-16 | Enzymatic construction material for repair and corrosion resistance and durability |
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| US11193054B2 (en) * | 2016-09-30 | 2021-12-07 | Baker Hughes, A Ge Company, Llc | Biologically mediated precipitation of carbonates for use in oilfield applications |
| US10647617B2 (en) * | 2017-02-24 | 2020-05-12 | Worcester Polytechnic Institute | Method for enzymatic repair of cementitious surfaces |
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