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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
2
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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Innovative solutions for a safer, better worldBUILDING STRONG®
Finite Element Analysis from ABAQUS on HPC – Gravity Loading
Vertical stresses(psi)
Vertical displacements (in)
Innovative solutions for a safer, better worldBUILDING STRONG®
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
Innovative solutions for a safer, better worldBUILDING STRONG®
Structural Testing
Innovative solutions for a safer, better worldBUILDING STRONG®
Shear test on wall section
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Innovative solutions for a safer, better worldBUILDING STRONG®
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.
Innovative solutions for a safer, better worldBUILDING STRONG®
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Obstacles
Jersey Barrier printed for Modern
Marine Expo
Last update (09-FEB-17)
Innovative solutions for a safer, better worldBUILDING STRONG®
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Culverts
Culvert printed for
Modern Marine Expo
Last update (09-FEB-17)
Innovative solutions for a safer, better worldBUILDING STRONG®
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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.
Last update (09-FEB-17)
Innovative solutions for a safer, better worldBUILDING STRONG®
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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
Last update (09-FEB-17)
Innovative solutions for a safer, better worldBUILDING STRONG®
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Innovative solutions for a safer, better worldBUILDING STRONG®
Additive Construction with ACES
Case Study and Research Requirements
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Innovative solutions for a safer, better worldBUILDING STRONG®
Where we started…
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January 2015
Innovative solutions for a safer, better worldBUILDING STRONG®
Where we started…
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Late February 2015
Innovative solutions for a safer, better worldBUILDING STRONG®
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
Innovative solutions for a safer, better worldBUILDING STRONG®
Where we started…
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8/18/2015
8/20/2015
9/28/2015
10/22/2015 10/23/2015
Innovative solutions for a safer, better worldBUILDING STRONG®
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Automated Construction of Expeditionary StructuresACES Build and Print Team
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
Innovative solutions for a safer, better worldBUILDING STRONG®
Innovative solutions for a safer, better worldBUILDING STRONG®
Innovative solutions for a safer, better worldBUILDING STRONG®
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Automated Construction of Expeditionary StructuresACES Build and Print Team
StructuresLast update (09-FEB-17)
ACES-2 Printed Entry Control Point (ECP).
A concrete printed building with a concrete printed roof.
Innovative solutions for a safer, better worldBUILDING STRONG®
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Automated Construction of Expeditionary StructuresACES Build and Print Team
Collaboration with NASA,
Jacobs, Contour
Crafting LLC
ACES-3 July, 2017Shown: 3D model
Last update (09-FEB-17)
Dry Good Storage Subsystem Liquid Storage Subsystem
Continuous Feedstock Mixing Delivery Subsystem (CFDMS)
• Accumulator• Pump Trolley• Gantry• Hose Management• Nozzle• Electrical & Software
+
Innovative solutions for a safer, better worldBUILDING STRONG®
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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
Innovative solutions for a safer, better worldBUILDING STRONG®
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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
Innovative solutions for a safer, better worldBUILDING STRONG®
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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
Innovative solutions for a safer, better worldBUILDING STRONG®
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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