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UFS researchers reimagine ancient stromatolites to advance Ecological Engineering Sciences

12 June 2025 | Story University of the Free State | Photo Supplied

Dr Hossein Naghizadeh and Refilwe Lediga — Collaborative innovation in action: Researchers from the University of the Free State’s Green Concrete Lab have partnered with the University of Johannesburg to advance 3D printing technologies using sustainable concrete materials. Pictured (from left): Dr Hossein Naghizadeh, Senior Lecturer in Engineering Sciences at UFS, and Refilwe Lediga, Concrete Printing Research Expert in the Department of Civil Engineering Technology at UJ.

In an ambitious and interdisciplinary effort to address today’s Grand Challenges, researchers at the University of the Free State (UFS) are exploring how nature’s oldest life forms – stromatolites – can inspire cutting-edge innovations in industrial ecology and marine conservation. Drawing from biomimicry, 3D printing, and microbial engineering, their work showcases the convergence of ecological insight with modern technology.

“One such example is replicating the structures of stromatolites – some of the earliest evidence of life - using green cement and 3D printing, the latest technology in industrial ecology,” explains Dr Jacques Maritz, Head of the Unit of Engineering Sciences at UFS.

Ancient structures, modern science

Stromatolites are layered microbial formations created by ancient cyanobacteria and date back over 3.5 billion years. These living fossils, found in fossil records and rare modern environments like Shark Bay in Australia, grow through a combination of photosynthesis, sediment trapping, and calcium carbonate precipitation. Not only do they support biodiversity, but they also play a vital role in natural carbon sequestration.

UFS researchers are harnessing the lessons from these ancient formations to address urgent environmental challenges. In particular, Dr Yolandi Schoeman, Senior Lecturer at the Centre for Biogeochemistry, is leading efforts to cultivate hybrid stromatolites in controlled environments, using microbial consortia grown on 3D-printed scaffolds.

“At UFS, we are reimagining stromatolite formation through both artificial structural replication and biological cultivation, bridging industrial ecology and microbial engineering to address modern environmental challenges,” says Dr Schoeman.

Ecological engineering for reef restoration

The rapid decline of marine biodiversity and the degradation of natural reef ecosystems have prompted ecological engineers to develop innovative solutions. At the UFS Green Concrete Lab, researchers are pioneering the design of artificial reefs using 3D-printed, low-carbon geopolymer concrete – a material formulated from industrial by-products such as fly ash and slag.

Artificial reefs mimic natural reef complexity and serve as critical habitats for marine life, from fish and crustaceans to coral polyps and algae. Algae, in particular, are key to marine ecosystems due to their roles in nutrient cycling, oxygen production, and carbon capture.

“Green concrete refers to concrete that utilises alternative binders and industrial by-products, significantly reducing the environmental footprint. At UFS, we are focusing on geopolymer concrete, which eliminates the high-energy processes associated with Portland cement, while offering greater chemical resistance - ideal for marine applications,” explains Dr Abdolhossein Naghizadeh from the Unit of Engineering Sciences.

3D printing nature’s complexity

One of the challenges in artificial reef development is replicating biologically inspired geometries that support diverse marine ecosystems. Traditional construction methods often fail in this regard, but additive manufacturing, or 3D concrete printing, is providing a solution.

The UFS Green Concrete Lab, in collaboration with the University of Johannesburg, is developing reef modules with intricate geometries and natural surface textures. These features support coral and algae attachment, accelerate ecological colonisation, and enhance habitat functionality. Biochar-based compost filters are also being integrated to aid algae-driven wastewater treatment.

A particularly novel avenue of research involves using 3D printing to recreate stromatolite structures. These serve as ancient blueprints for modern reef design, merging deep-time ecological understanding with advanced material science.

Biologically engineered hybrid stromatolites

In parallel to structural efforts, UFS is advancing biological approaches to stromatolite cultivation. From July 2025, researchers in the Unit of Engineering Sciences will initiate a large-scale experiment using microbial consortia in 60-litre tanks, scaling up to 1 m² hypersaline ponds. 3D-printed conical scaffolds, coated with materials such as PP-CaCO₃, hydroxyapatite, and silica gel, will accelerate microbial colonisation and lamination.

The goal: to achieve stromatolite growth of 14-16 mm in just 28 days - over 150 times faster than in nature. These hybrid systems are expected to produce 7-8 mg/L/day of oxygen, sequester carbon at 3.2 g/m²/day, and remove up to 90% of nitrates and phosphates from water. The potential applications extend from terrestrial ecosystem restoration to extraterrestrial life-support systems.

A multidisciplinary vision for sustainability

This work exemplifies the strength of interdisciplinary research at UFS, combining civil engineering, mechatronics, marine ecology, chemistry, microbiology, and digital fabrication. The Ecological Engineering Sciences stream fosters a vibrant environment for postgraduate students to develop practical, impactful solutions.

The Green Concrete Lab is central to these efforts, offering students and researchers access to advanced technologies and collaborative networks. Through their innovative work in 3D-printed green concrete and microbial systems, UFS researchers are addressing biodiversity loss, advancing sustainable construction, and contributing to the global climate agenda.

“Whether it's rethinking materials, restoring ecosystems, or redefining what concrete can be, our research is laying the foundation for a better, more sustainable world beneath the waves,” concludes Dr Maritz.

News Archive

Inaugural lecture: Prof Robert Bragg, Dept. of Microbial, Biochemical and Food Biotechnology

2006-05-17

Attending the inaugural lecture were in front from the left Prof Robert Bragg (lecturer at the Department of Microbial, Biochemical and Food Biotechnology) and Frederick Fourie (Rector and Vice-Chancellor). At the back from the left were Prof James du Preez (Departmental Chairperson: Department of Microbial, Biochemical and Food Biotechnology) and Prof Herman van Schalkwyk (Dean: Faculty of Natural and Agricultural Sciences). Photo: Stephen Collett

A summary of an inaugural lecture delivered by Prof Robert Bragg at the University of the Free State:

CONTROL OF INFECTIOUS AVIAN DISEASES – LESSONS FOR MAN?

Prof Robert R Bragg
Department of Microbial, Biochemical and Food Biotechnology
University of the Free State

“Many of the lessons learnt in disease control in poultry will have application on human medicine,” said Prof Robert Bragg, lecturer at the University of the Free State’s (UFS) Department of Microbial, Biochemical and Food Biotechnology during his inaugural lecture.

Prof Bragg said the development of vaccines remains the main stay of disease control in humans as well as in avian species. Disease control can not rely on vaccination alone and other disease-control options must be examined.

“With the increasing problems of antibiotic resistance, the use of disinfection and bio security are becoming more important,” he said.

“Avian influenza (AI) is an example of a disease which can spread from birds to humans. Hopefully this virus will not develop human to human transmission,” said Prof Bragg.

According to Prof Bragg, South Africa is not on the migration route of water birds, which are the main transmitters of AI. “This makes South Africa one of the countries less likely to get the disease,” he said.

If the AI virus does develop human to human transmission, it could make the 1918 flu pandemic pale into insignificance. During the 1918 flu pandemic, the virus had a mortality rate of only 3%, yet more than 50 million people died.

Although the AI virus has not developed human-to-human transmission, all human cases have been related to direct contact with infected birds. The mortality rate in humans who have contracted this virus is 67%.

“Apart from the obvious fears for the human population, this virus is a very serious poultry pathogen and can cause 100% mortality in poultry populations. Poultry meat and egg production is the staple protein source in most countries around the world. The virus is currently devastating the poultry industry world-wide,” said Prof Bragg.

Prof Bragg’s research activities on avian diseases started off with the investigation of diseases in poultry. “The average life cycle of a broiler chicken is 42 days. After this short time, they are slaughtered. As a result of the short generation time in poultry, one can observe changes in microbial populations as a result of the use of vaccines, antibiotics and disinfectants,” said Prof Bragg.

“Much of my research effort has been directed towards the control of infectious coryza in layers, which is caused by the bacterium Avibacterium paragallinarum. This disease is a type of sinusitis in the layer chickens and can cause a drop in egg product of up to 40%,” said Prof Bragg.

The vaccines used around the world in an attempt to control this disease are all inactivated vaccines. One of the most important points is the selection of the correct strains of the bacterium to use in the vaccine.

Prof Bragg established that in South Africa, there are four different serovars of the bacterium and one of these, the serovar C-3 strain, was believed to be unique to Southern Africa. He also recently discovered this serovar for the first time in Israel, thus indicating that this serovar might have a wider distribution than originally believed.

Vaccines used in this country did not contain this serovar. Prof Bragg established that the long term use of vaccines not containing the local South African strain resulted in a shift in the population distribution of the pathogen.

Prof Bragg’s research activities also include disease control in parrots and pigeons. “One of the main research projects in my group is on the disease in parrots caused by the circovirus Beak and Feather Disease virus. This virus causes serious problems in the parrot breeding industry in this country. This virus is also threatening the highly endangered and endemic Cape Parrot,” said Prof Bragg.

Prof Bragg’s research group is currently working on the development of a DNA vaccine which will assist in the control of the disease, not only in the parrot breeding industry, but also to help the highly endangered Cape Parrot in its battle for survival.

“Not all of our research efforts are directed towards infectious coryza or the Beak and Feather Disease virus. One of my Masters students is currently investigating the cell receptors involved in the binding of Newcastle Disease virus to cancerous cells and normal cells of humans. This work will also eventually lead to a possible treatment of cancer in humans and will assist with the development of a recombinant vaccine for Newcastle disease virus,” said Prof Bragg.

We are also currently investigating an “unknown” virus which causes disease problems in poultry in the Western Cape,” said Prof Bragg.

“Although disinfection has been extensively used in the poultry industry, it has only been done at the pre-placement stage. In other words, disinfectants are used before the birds are placed into the house. Once the birds are placed, all use of disinfectants stops,” said Prof Bragg.

“Disinfection and bio security can be seen as the ‘Cinderella’ of disease control in poultry. This is also true for human medicine. One just has to look at the high numbers of people who die from hospital-acquired infections to realise that disinfection is not a concept which is really clear in human health care,” said Prof Bragg.

Much research has been done in the control of diseases through vaccination and through the use of antibiotics. “These pillars of disease control are, however, starting to crumble and more effort is needed on disinfection and bio security,” said Prof Bragg.

Prof Bragg has been working in close co-operation with a chemical manufacturing company in Stellenbosch to develop a unique disinfectant which his highly effective yet not toxic to the birds.

As a result of this unique product, he has developed the continual disinfection program for use in poultry. In this program the disinfectant is used throughout the production cycle of the birds. It is also used to ensure that there is excellent pre-placement disinfection.

“The program is extensively used for the control of infectious diseases in the parrot-breeding industry in South Africa and the product has been registered in 15 countries around the world with registration in the USA in the final process,” said Prof Bragg.

“Although the problem of plasmid mediated resistance to disinfectants is starting to rear its ugly head, this has allowed for the opening of a new research field which my group will hopefully exploit in the near future,” he said.

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