Non-reactive biochar and Bacillus pumilus RSB17-based healing powder: A sustainable solution for enhanced bacterial viability in self-healing mortar

Abstract

Existing mortar uses self-healing powders that are based on mineral admixtures, whose reactive nature negatively impacts bacterial viability and diminishes their effectiveness over time. This study aims to develop non-reactive, sustainable biochar-based healing powders with extended bacterial viability to serve as self-healing admixture in bio-mortar. Biochar from coconut husk, coconut shell, and coconut leaf petiole was evaluated for compatibility with Bacillus pumilus RSB17, emphasizing bacterial growth and calcium carbonate precipitation. Coconut shell biochar demonstrated superior performance and was used to formulate a microbial biochar healing powder. Another healing powder was prepared by lyophilizing the bacterial spore solution without protectants. The shelf life was evaluated for 180 days at 4 °C and 25 °C, demonstrating that microbial biochar healing powder at 4 °C maintained bacterial viability above the 4.5 log CFU/g threshold necessary for effective calcium carbonate precipitation, while lyophilized spore powder stored at 25 °C dropped below the threshold at 90 days. Microbial biochar healing powder stored at 4 °C for 180 days was integrated into the mortar, which healed crack width up to 0.80 mm at 56 days under submerged rainwater maintained at 27 °C ± 2 °C and 85 % ± 5 % relative humidity. Electrical resistivity decreased from 28.16 ?·m to 21.35 ?·m, the permeability coefficient dropped from 153.90 mm/s to 0 mm/s, and compressive strength regained 90.53 %, which collectively indicated enhanced self-healing. Microstructural analysis confirmed the stable cuboid calcite crystals with a crystallite size of 86.62 nm. Thus, Microbial biochar healing powder produced from coconut shell biochar and Bacillus pumilus RSB17 and stored at 4 °C is an effective self-healing admixture for bio-mortar applications with a minimum storage period of 180 days. © 2025 Elsevier B.V.