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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

R40 million construction contract with black empowerment group starts at UFS
2006-09-04

During the ceremonial kick-off of the biggest construction project in the history of the UFS were from the left: Ms Vuyiwe Mkhupha (Manager of   Sikeyi Construction), Prof Frederick Fourie (Rector and Vice-Chancellor of the UFS) and Prof Steve Basson (Head of the UFS Department of Chemistry). Photo: (Gerhard Louw)

R40 million construction contract with black empowerment group starts at UFS   

The biggest construction contract in the history of the University of the Free State (UFS) to the value of R40 million has started on the Main Campus in Bloemfontein.  The contractors are Ströhfeldt Construction, in a joint venture with Sikeyi Construction, a black empowerment partner.

The contract comprises the extensive modernising, refurnishing and extension of the Chemistry Building.  This is the highest amount the UFS has ever spent on the refurnishing of a building. 
 
A number of initiatives have contributed to the fact that the UFS Department of Chemistry is one of the foremost chemistry departments in the country:
 

  • Expensive equipment and apparatus to the value of almost R20 million were acquired by the department the past year;
  • The basis of this is a strategic partnership with Sasol, the biggest research and development company  in the country;
  • The purchase of the most advanced 600MHz nuclear magnetic resonance spectro meter in Africa;
  • The purchase of a single crystal X-ray diffractometer; and
  • The purchase of a differential scanning calorie meter, used to test the effect of heat on chemicals.  This apparatus comprises of the most advanced detectors in the world.

“Natural scientists need the necessary equipment, apparatus and laboratories to be able to exercise world-class science.  Three years ago the UFS top management made a strategic decision to focus strongly on research and on our  laboratories and lecture halls,“ said Prof Frederick Fourie, Rector and Vice-Chancellor of the UFS, during the launch of the Chemistry Building’s refurbishment.

“I regard this project as a symbol of our investment in science and the academy,“ said Prof Fourie.

Prof Fourie said that the UFS spent almost R100 million in the last 5 years to renovate the Main Campus.  New buildings such as Thakaneng Bridge were built and other such as the Reitz Dining Hall was renovated and converted into the Centenary Complex.  “These projects, together with the refurbishment of the Chemistry Building, also show how the UFS contributes to the development and growth of not only Bloemfontein, but also how we invest in the Free State,“ said Prof Fourie.

According to Ms Edma Pelzer, Director: Physical Planning and Special Projects at the UFS, the current building originally comprised of the Moerdyk Building built in 1949 and a newer wing built in 1966.  This building became too small and obsolete and a new part is now being added to the eastern side.
  
According to Ms Pelzer a great deal of the project comprises the dramatic upgrading and modernising of laboratories, existing mechanical systems and the installation of new systems.  “The nature of the work of staff and students demands sophisticated mechanical systems such as air conditioning, fume hoods, the provision of gas, etc and therefore these received specific attention.  The research laboratories, lecture laboratories and office areas will also be separated for safety and greater efficiency,” said Ms Pelzer.

“Interesting design solutions for the complex needs of the department were found and I foresee that the building and its immediate environment will be an adornment to the Main Campus after its expected completion in 2008,” said Ms Pelzer.

Media release
Issued by: Lacea Loader
Media Representative
Tel:  (051) 401-2584
Cell:  083 645 2454
E-mail:  loaderl.stg@mail.uovs.ac.za
14 September 2006

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