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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

UFS receives R13,7 Million for Research into Prehistoric Organisms

2007-03-27

Some of the guests attending the launch of the research contract are: Dr Siyabulela Ntutela (Deputy Director: Biotechnology at the Department of Science and Technology), Dr Godfrey Netswera (Manager of Thuthuka and the Support Programme at the National Research Foundation (NRF)), Dr Esta van Heerden (Platform Manager and lecturer at the Department of Microbial, Biochemical and Food Biotechnology at the UFS), Mr Butana Mboniswa (Chief Executive Officer of BioPAD), and Mr Vuyisele Phehani (Portfolio Manager for BioPAD).
Photo: Leonie Bolleurs

The University of the Free State (UFS) has been awarded a massive R13,7 million contract to conduct research into prehistoric micro-organisms which live under extreme conditions, for example in mineshafts.

This is one of the biggest research contracts awarded to the UFS in recent years.

The biotechnology research contract was awarded to the UFS by BioPAD, a South African biotechnology company that brokers partnerships between researchers, entrepreneurs, business, government and other stakeholders to promote innovation and create sustainable biotechnology businesses.

The project is endorsed by the Department of Science and Technology and the National Research Foundation (NRF), which contributes to the bursaries of the 17 postgraduate students on the programme.

The contract involves the establishment of a Platform for Metagenomics - a technique which allows researchers to extract the DNA from microbes in their natural environment and investigate it in a laboratory.

“Through this platform we will be able to understand deepmine microbial populations
and their potential application in the search for life in outer space. It is most likely
that, if life were to be found on other planets in our solar system, it would probably
resemble that which existed millions of years ago on earth. Apart from all this, these
organisms have unique properties one can exploit in biotechnological application for
South Africa and its community,” said Dr Esta van Heerden, platform manager and
lecturer at the UFS Department of Microbial, Biochemical and Food Biotechnology.
She is assisted by her collegues, Prof. Derek Litthauer and Dr Lizelle Piater.

“The platform aims to tap into the unique genetic material in South African mines
which will lead to the discovery of new genes and their products. These new and unique products will find application in the medical field (anti-cancer, anti-bacterial en anti-viral cures), the industrial sector (nanotechnology, commercial washing agents and the food industry), environmental sector (pollution management, demolition of harmful metals and other toxic waste),” said Dr Van Heerden.

According to Dr Van Heerden, the Metagenomics Platforms stems from the Life in
Extreme Environments (LExEN) programme which was started in 1994 by Princeton
University in the United States of America (USA) in South African mines with grants
from among others the National Aeronautics and Space Administration (NASA) and
the National Science Foundation (NSF) in the USA. Other international collaborators
on the project include Geosynec Consultants Inc. (USA), Oak Ridge National
Laboratory (USA), the University of Tennessee (USA) and in South Africa the
Universities of the Witwatersrand, North West and Limpopo and companies like BHP
Billiton, MINTEK and mining companies like Harmony, Gold Fields and AngloGold
Ashanti.

The research field laboratory of the Metagenomics Platform, which was situated in
Glen Harvey, was moved to the Main Campus of the UFS in Bloemfontein. “In this
way the university has become the central hub for all research programmes. We are
also the liaison between the LExEN programme and the various mining companies
involved,” said Dr Van Heerden. The new laboratory was introduced during the
launch of the research contract.

“Our decision to commit BioPAD to this project stems from the company’s commitment to advance human capacity development to strengthen South Africa’s research infrastructure. It is also part of our aim to create and protect intellectual property,” said Mr Butana Mboniswa, Chief Executive Officer of BioPAD.

Talking on behalf of the UFS senior management, Prof. Teuns Verschoor, Vice-Rector
of Academic Operations, said that the university shares the excitement to be part of
the exploration of unknown forms of life, the discovery of new genes and
their products and in applying newly gained knowledge to better understand our
universe.

Media release
Issued by: Lacea Loader
Assistant Director: Media Liaison
Tel: 051 401 2584
Cell: 083 645 2454
E-mail: loaderl@ufs.ac.za
27 March 2007

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