Automated Construction of Expeditionary Structures (ACES)...BUILDING STRONG Innovative solutions for...

Automated Construction of Expeditionary Structures (ACES)Michael P. Case, Ph.D.Program Manager

Megan A. Kreiger, MSDesign and Build Team Leader

NSF Workshop on Additive Manufacturing (3D-Printing for Civil Infrastructure Design and Construction

U.S. Army Engineer Research and Development Center Construction Engineering Research Laboratory.July 14, 2017

Distribution Statement A — Distribution is approved for public release. Distribution is unlimited.

Mission• Increase force protection capabilities in different

environments• Minimize the impact of the environment on the Army

mission• Minimize the impact of Army activities on the

environment

Field OfficesLaboratories

HQ

7 Laboratories2500 Employees

Research Areas• Civil Works/Water Resources • Environmental Quality/Installations • Military Engineering (protection, infrastructure)• Geospatial Research and Engineering (data in

space and time, Environmental intel)

US Army Engineer Research and Development Center

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CRREL

GRL

CHL

GSL

ITL

EL

CERL

$1B – FY15 programCoastal & Hydraulics Laboratory

Cold Regions Research & Engineering Laboratory

Construction Engineering Research Laboratory

Environmental Laboratory

Geotechnical & Structures Laboratory

Geospatial Research Laboratory

Information Technology Laboratory

Vision - Capability to print custom-designed expeditionary structures on-demand, in the

field, using locally available materials.

WHAT IS IT?• Prototype automated construction system that can

fabricate a 500 ft2 structure < 24 hours.• Cementitious materials and structural assemblies• Robotic positioning, material handling, and control

systems• Finite element structural analysis of layered fresh

concrete properties using HPC• Characterization of energy behavior• Characterization of blast effect and fragment

penetration • Automated slicing of 3D designs for printing

WHAT DOES IT OFFER?• Reduced construction time from 4-5 days to 1

day • Reduced Soldier/Contractor requirements for

construction from 8 personnel to 3 personnel per structure.

• Reduced logistics impact associated with materials shipped, personnel and resources to sustain the structures and personnel

• Decreased material shipped from out of theater from 5 tons to less than 2.5 tons.

Collaborators:► NASA (Marshall, Kennedy)► Caterpillar, Inc. (CRaDA)► Contour Crafting Corporation► Oak Ridge National Laboratory

ACES Technically SpeakingTECHNICAL APPROACH:

ACES 1 – ¼ scale (FY15-16)► Prototype robotic system► Investigate cementitious materials► Destructively test wall & beam sections

ACES 2 – full scale (FY 16)► 18’ x 34’ print envelope► Incorporate dry & wet delivery, nozzle, controls

(NASA, CCC, Caterpillar)► Print guard hut & B-Hut prototypes► Structural modeling

ACES 3 – mobile (FY 16-17)► Increase automation (fewer people)► Transportable (Palletized Load System)► Energy modeling► Trade space analysis► Blast & penetration testing► Proof-of-concept B-Hut demonstration

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Innovative solutions for a safer, better worldBUILDING STRONG®

ACES Project Team Engineer Research Development Center (ERDC)

► Construction Engineering Research Laboratory (CERL)► Cold Regions Research and Engineering Laboratory (CRREL) ► Geotechnical and Structures Laboratory (GSL)► Information Technology Laboratory (ITL)

NASA ► Marshall Space Flight Center ► Kennedy Space Center

Contour Crafting Corporation Caterpillar (CRADA) Oak Ridge National Laboratory (MIPR) Structural assessment/code compliance by

SOM - Skidmore, Owings, & Merrill

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Finite Element Analysis from ABAQUS on HPC – Gravity Loading

Vertical stresses(psi)

Vertical displacements (in)


Use of Early Age Strength in Analyses

For 8’ high walls for a 16’x32’ b-hut:► For 1” layers – 15 min per layer► 1 foot high pour requires 3 hours► Concrete will be placed on

subsequent layers before initial or final set has occurred

A user material subroutines in ABAQUS to capture the early age strength variation based on lab tests of concrete samples


Structural Testing


Shear test on wall section

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Vapor Barrier Requirements

Need at least VB of 0.1 Perms or greater, impermeable paint with anti-fungal

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Substrate category 0: Optimal culture medium. Substrate category I: Biologically recyclable building

materials like wall paper, plaster, cardboard, building materials made of biologically degradable raw materials, material for permanent elastic joints.

Substrate category II: Biologically adverse recyclable building materials such as renderings, mineral building material, certain wood as well as insulation material not covered by I.

Substrate K: Building materials that are neither degradable nor contain nutrients.


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Obstacles

Jersey Barrier printed for Modern

Marine Expo

Last update (09-FEB-17)


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Culverts

Culvert printed for

Modern Marine Expo



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BAAM/Concrete Hybrid Structures

Collaboration with Oak Ridge National Lab

regarding use of on-site printing of lightweight structural

members using a variety of plastics.

Shown: Carbon fiber infused exemplars of various structural members awaiting

destructive testing in cooperation with University of Illinois, Urbana-Champaign.



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Automated Construction of Expeditionary StructuresACES Build and Print Team

Customization of the Oak Ridge National Lab

Slicer software to work with ACES2



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Additive Construction with ACES

Case Study and Research Requirements

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Where we started…

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January 2015


Where we started…

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Late February 2015


Where we started…

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8/10/2015 8/11/2015 Air pockets…

8/12/2015 8/13/2015

Droop on corners from missed area.

8/17/2015Material change


Where we started…

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8/18/2015

8/20/2015

9/28/2015

10/22/2015 10/23/2015


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Progress

ACES-232’ x 16’ x 9’ Print EnvelopeRotating NozzleComplex Shapes

ACES-13’ x 4’ x 4’ Print Envelope

Simple Shapes to Test Robotic Motion

Over 100 experiments later

March 2016


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StructuresLast update (09-FEB-17)

ACES-2 Printed Entry Control Point (ECP).

A concrete printed building with a concrete printed roof.


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Collaboration with NASA,

Jacobs, Contour

Crafting LLC

ACES-3 July, 2017Shown: 3D model


Dry Good Storage Subsystem Liquid Storage Subsystem

Continuous Feedstock Mixing Delivery Subsystem (CFDMS)

• Accumulator• Pump Trolley• Gantry• Hose Management• Nozzle• Electrical & Software

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Automated Construction of Expeditionary Structures ACES B-hut 1 Architecture

Print at ERDC Forward Operating Base Lab (EFOB-L) in Summer 2017


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Full-scale 3D Printed Concrete Building

16’ x 32’ x 7’8” – Finished printing on June 27,2017Based off of standard B-hut design


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Research Requirements

Still a lot of work for the community to do:►Material options►Open time for printing►Drying shrinkage►Real time rheology sensing and feedback►Reinforcement, especially vertical►Batching and mixing►Velocity and flow control►Print quality feedback►As-built QA


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Automated Construction of Expeditionary StructuresACES Team

Last update (07-JUL-17)

Questions?Special thanks for ACES content and images to:• Mike Case• Ghassan Al-Chaar• Marion Banko• Brandy Diggs• Megan Kreiger• Eric Kreiger• Richard Liesen• Russ Northrup• Matt Schapen• Pete Stynoski• Jacob Wagner• Justine Yu

Automated Construction of Expeditionary Structures (ACES)...BUILDING STRONG Innovative solutions for...

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