The first consolidation method investigated is muffle furnace-based sintering, which mimics firing processes for producing commercial clay-based bricks. A protocol for both green and brown part (bricks) production is first established, followed by evaluation of compressive (unconfined) strengths of the produced bricks. The micromechanics of particle coalescence in solid state sintering of lunar regolith is evaluated using techniques derived from classical ceramic sintering. Additionally, consolidation of regolith simulants rich in glassy basalt is studied using both solid state and liquid state sintering. Final failure modes via multiple crack nucleation and growth are also investigated. Production of bricks with compressive strengths of upto 55 MPa is demonstrated via the sintering process.

The third method involves the use of microbial-induced calcite Precipitation (MICP) for creating consolidates, termed space bricks, using lunar and Martian regolith simulants. Incorporating Sporosarcina pasteurii bacteria, a ureolytic pathway is initiated. Adding guar gum and NiCl2 significantly enhances compressive strength, making the bricks comparable to commercially used mud bricks. Including glass fiber, while slightly reducing strength, enables machinability for precise shaping without specialized molds. This approach, validated through detailed microscopy and analytical techniques, presents a promising avenue for robust extra-terrestrial structures, aligning with in situ resource utilization principles.

Finally, the use of BRC as a lower strength cementing material for joining sintered bricks in the form of a wall is studied. Failure mechanisms at the wall level, including crack paths and potential Cook-Gordon type strengthening are investigated under quasi static tension/ compression tests as well as high-velocity projectile impact.