Building a Greener Future: Biocement, Bioconcrete, and the Rise of Biomanufacturing

The construction industry, responsible for 8–10% of global CO₂ emissions, faces a reckoning. Concrete and steel—cornerstones of modern cities—are both environmental liabilities. Cement production alone generates 2.5 billion tons of CO₂ annually, while steelmaking guzzles energy at scorching temperatures. These materials also degrade over time, crumbling under stress, weather, and conflict in vulnerable regions. But a quiet revolution is underway, driven by biology. Biocement, bioconcrete, and biomanufacturing are redefining construction, offering self-healing, low-carbon alternatives that could slash emissions and build resilience in an era of climate crises.

From Microbes to Megastructures: The Science of Bio-Based Materials

Biocement and bioconcrete are pioneering materials produced through biomineralization, a process where microorganisms, particularly bacteria, precipitate minerals like calcium carbonate within a construction material.

Biocement harnesses microorganisms like Sporosarcina pasteurii to mimic nature’s limestone formation. Through microbial-induced calcite precipitation (MICP), bacteria convert calcium sources and urea into calcium carbonate, binding materials without the 1,450°C kilns used in traditional cement. This process cuts energy use by up to 90%, repurposes industrial waste (e.g., fly ash), and even works in seawater—making it ideal for marine infrastructure.

Bioconcrete takes this further by embedding bacteria directly into concrete mixes. When cracks form, water activates dormant spores (e.g., Bacillus pseudofirmus), triggering limestone production that seals gaps autonomously.The result is a self-healing material that can repair its own cracks and damage over time, thanks to the ongoing activity of the embedded bacteria.  Dutch trials show this extends structure lifespans by 30–50%, reducing repair costs and emissions from rebuilds. The ability to repair itself automatically when exposed to water could lead to longer-lasting roads, bridges, and buildings, ultimately contributing to lower carbon footprints and reduced resource consumption.

One notable example is BioLITH Tiles, a U.S.-based startup producing tiles from biocement formed through microbial processes. These tiles cure faster and with far less environmental impact than standard cement products, making them ideal for green construction. In parallel, researchers at Delft University of Technology have created a form of self-healing concrete, embedding bacteria that activate upon crack formation to produce calcium carbonate and seal the damage—significantly enhancing the longevity and reducing lifecycle maintenance of structures. Meanwhile, the EU-funded ReSHEALience project is applying bioconcrete to bolster infrastructure in aggressive environments like marine and coastal regions, showing how this technology can protect and extend the life of bridges, sea walls, and industrial facilities. Collectively, these examples highlight the transformative potential of biocement and bioconcrete in building more resilient, sustainable infrastructure

The Biomanufacturing Blueprint: Faster, Cleaner, Smarter

Biomanufacturing processes, particularly the development of biocement and bioconcrete, represent a transformative shift in the construction industry—moving from traditional, resource-intensive methods toward more sustainable, adaptive solutions. These biologically engineered materials are not only environmentally friendly but also exhibit unique properties such as self-healing and low energy production requirements.

The microbial-induced calcium carbonate precipitation (MICP) process that underpins biocement and bioconcrete production follows a highly controlled series of steps, from selecting and cultivating specific bacteria to integrating them into construction substrates.

The process begins with selecting bacteria strains (e.g., Bacillus subtilis) optimized for specific environments. These microbes are fed agricultural or industrial waste, such as rice husks or slag, to produce biocement. Integration with AI allows real-time strength monitoring, while 3D printing enables precision construction.

Mycelium composites (fungi-grown panels) and algae-based polymers are expanding the toolkit. In 2023, Ecovative Design partnered with Gensler to prototype mycelium office partitions that decompose post-use, embodying circular design. Similarly, Algenesis developed algae-derived polyurethane foams for insulation, reducing reliance on fossil fuels.

 By harnessing the capabilities of microorganisms like Sporosarcina pasteurii, engineers can create construction materials that actively respond to environmental damage, making them especially valuable in disaster-prone or infrastructure-scarce regions. As these processes mature, their adaptability to various environmental conditions could revolutionize how structures are built in remote or extreme settings.

This precision opens the door for further innovation—particularly in combining biomanufacturing with cutting-edge technologies like artificial intelligence and 3D printing. AI could be used to monitor microbial activity in real time and fine-tune conditions for optimal performance, while 3D printing can be paired with these biologically engineered materials to construct complex, customized buildings on demand. For example, COBOD’s 2023 partnership with Holcim introduced a robotic arm that 3D-prints bioconcrete walls with embedded bacteria for self-repair. This synergy between biology and digital fabrication hints at a future where construction becomes more sustainable, autonomous, and resilient.

Innovations in Action: From Battlefields to Smart Cities

Military Mobility Reinvented

At the 2023 AFA Warfare Symposium, the U.S. Air Force showcased biocement bricks made in 96 hours using soil, bacteria, and urea. This innovation supports Agile Combat Employment, enabling rapid runway construction in remote areas without heavy machinery.Developed through a biomanufacturing process that uses Sporosarcina pasteurii bacteria to convert a mixture of urea and road salt into calcium carbonate, these bricks exemplify a scalable, field-adaptable method of hardening soil. This breakthrough is particularly well-suited to the U.S. Air Force’s Agile Combat Employment (ACE) strategy, which focuses on quickly establishing operational airstrips in austere, contested environments. Unlike traditional methods requiring heavy equipment and extended setup times, biocement enables airmen to construct functional landing surfaces in under 96 hours—dramatically increasing speed and flexibility in forward deployments. Recent trials in Nevada demonstrated biocement’s ability to withstand heavy aircraft loads, with the Air Force Research Laboratory (AFRL) targeting deployment by 2025.

Self-Healing Cities

The EU’s ReSHEALience project deploys bioconcrete in bridges and coastal defenses across Italy and Portugal. In Rotterdam, a bioconcrete bike path repairs its own cracks, while Delft University’s “Living Lab” buildings use bacteria to combat erosion. Startups like BioMason and Biomasonry now produce carbon-negative bricks, cutting 880 million tons of annual emissions if scaled globally. In 2023, Singapore’s Urban Redevelopment Authority approved bioconcrete for public infrastructure, citing its success in reducing maintenance costs by 40% in pilot projects.

Waste to Wealth

BioLITH’s tiles, made from industrial byproducts and bacteria, cure in hours instead of weeks. Meanwhile, Singapore’s SUTD pioneers 3D-printed biocement reefs to restore marine ecosystems—a dual solution for coastal protection and biodiversity. In 2024, the startup Cemvita announced a breakthrough using genetically modified algae to produce biocement from CO₂ emissions, achieving carbon-negative production at scale

Challenges and Latest Developments

Despite its environmental promise, biocement continues to face several hurdles before it can become a mainstream construction material. One of the key limitations is material strength, which typically ranges from 10 to 25 MPa—lower than traditional concrete’s 20 to 40 MPa. However, 2023 marked a turning point: researchers at Nanyang Technological University enhanced biocement’s performance by incorporating graphene oxide, increasing compressive strength by 40% and bringing it closer to conventional benchmarks. Production costs, another major barrier, are also falling. Biotech company Cemvita engineered microbes that reduced production expenses by half, targeting a drop from $120 per ton to just $50 per ton by 2025.

The latest developments in biocement and bioconcrete reflect significant strides in performance, cost-effectiveness, and scalability—key factors driving their transition from experimental materials to practical construction solutions. Recent research has focused on enhancing material properties such as compressive strength, durability, and resistance to water infiltration. These improvements are helping biocement and bioconcrete close the performance gap with conventional materials. Notably, additives like graphene oxide and optimized bacterial strains have shown great promise in boosting the mechanical integrity and self-healing abilities of these biomaterials, making them increasingly viable for structural applications.

The Road Ahead: A Living Built Environment

Conclusion: Building Alive—A New Era of Regenerative Construction

Biocement and bioconcrete have transcended their experimental origins to become cornerstones of a regenerative future. No longer confined to labs, these technologies are now shaping skylines, roads, and communities. When paired with AI-driven design, 3D printing precision, and forward-thinking policy, they chart a viable path to halving construction emissions by 2040. But their impact extends beyond carbon reduction: they redefine how we interact with the built environment. As MIT’s Mediated Matter Lab declares, “The future of construction isn’t just green—it’s alive.”

This paradigm shift merges sustainability with resilience. Biocement’s self-healing properties and bioconcrete’s waste-absorbing capabilities are not merely incremental improvements—they are foundational changes to an industry long reliant on extractive practices. Imagine infrastructure that repairs itself after earthquakes, buildings that sequester carbon as they age, or military bases rapidly assembled in remote regions using locally sourced bio-materials. These possibilities are no longer speculative; they are actionable today.

For architects, the mandate is to embrace biology as a co-designer. For policymakers, it’s to incentivize circular material standards and fund scalable pilots. For communities, it’s to champion projects that prioritize planetary health alongside human needs. The integration of bio-based materials into mainstream construction isn’t just an environmental imperative—it’s an economic and social opportunity to build infrastructure that endures, adapts, and regenerates.

The age of static, wasteful construction is ending. In its place rises a dynamic, living ecosystem of materials and methods that harmonize with nature rather than exploit it. The future isn’t being built with mere bricks—it’s growing, healing, and evolving, one biobrick at a time.