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All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

The Disruptive Technology That is Additive Construction: System Development Lessons Learned for Terrestrial and Planetary Applications

Disruptive technologies are unique in that they spawn other new technologies and applications as they grow. These activities are usually preceded by the question, "What If?" For example, "What if we could use an emerging technology and in-situ materials to promote exploration on the Moon or Mars, and then use that same technology to keep our troops out of harm's way and/or help the worlds' homeless?" This question allows us to flip the mindset of "how can people create more valuable innovation?" to "how can innovation create more valuable people?." This approach allows us to view augmented human labor as an inclusive opportunity, not a threat. The discipline of Additive Construction is growing rapidly due to the flexibility, speed, safety and logistics benefits offered as compared to standard construction techniques. Additive construction is a disruptive technology in that it employs the principles of additive manufacturing on a human habitat structure scale. Developed initially for emergency management and disaster relief applications, additive construction has now grown into military infrastructure and planetary (Moon and Mars) surface infrastructure applications as well. Additive Construction with Mobile Emplacement (ACME) is a NASA technology development project that seeks to demonstrate the feasibility of constructing shelters for human crews, and other surface infrastructure, on the Moon or Mars for a future human presence. The ACME project will allow, for the first time, the 3-dimensional printing of surface structures on planetary bodies using local materials for construction, thereby tremendously reducing launch and transportation mass and logistics. Some examples of infrastructure that could be constructed using robotic additive construction methods are landing pads, rocket engine blast protection berms, roads, dust free zones, equipment shelters, habitats and radiation shelters. Terrestrial applications include the development of surface structures using Earth-based materials for emergency response, disaster relief, general construction, and housing at all economic levels. This paper will describe the progress made by the NASA ACME project with a focus on prototypes and full scale additive construction demonstrations using both Portland cement concrete and other indigenous material mixtures. Rationale for the use of additive construction for both terrestrial and planetary applications will be explored and a thorough state-of-the-art of additive construction techniques will be presented. An evolutionary history of NASA's additive construction development efforts, dating back to 2004, will be included. The paper will then step through a series of trade studies performed to inform key processing and design decisions in the development of the full-scale ACES-3 system developed by NASA and the Jacobs Space Exploration Group for the U.S. Army Corps of Engineers (USACE) Construction Engineers Research Laboratory (CERL) in Champaign, IL. The selection of aggregate and binders, based on in-situ materials, will also be presented and discussed

Space Processing↗
NASA NTRS1991

Systems engineering studies of lunar base construction

Many ingenious concepts have been proposed for lunar base construction, but few systematic studies exist which relate time-consistent lunar base construction technologies and the choice of lunar base approach with the long-term SEI objectives - i.e., lunar indigenous base construction and Mars Exploration equipment development. To fill this gap, CSC has taken a two-pronged approach. First, the Center undertook basic geotechnical investigations of lunar soil, fabrication of a scale prototype of a lunar construction crane, a multi-robot construction team laboratory experiment, and a preliminary design of lunar base structures. Second, during Jun. and Jul. 1991 two lunar base construction systems engineering studies were accomplished - a 'near term lunar base' study, and a 'far-term lunar base' study. The goals of these studies were to define the major lunar base construction research problems in consistent technology/construction frameworks, and to define design requirements for construction equipment such as a lunar crane and a regolith mover. The 'near-term lunar base' study examined three different construction concepts for a lunar base comprised of pre-fabricated, pre-tested, Space Station Freedom-type modules, which would be covered with regolith shielding. Concept A used a lunar crane for unloading and transportation; concept B, a winch and cart; and concept C, a walker to move the modules from the landing site to the base site and assemble them. To evaluate the merits of each approach, calculations were made of mass efficiency measure, source mass, reliability, far-term base mass, Mars base mass, and base assembly time. The model thus established was also used to define the requirements for crane speed and regolith mover m(sup 3)/sec rates. A major problem addressed is how to 'mine' the regolith and stack it over the habitats as shielding. To identify when the cost of using indigenous lunar materials to construct the base exceeds the cost of development and delivery of the equipment for processing lunar materials, a study of construction of a candidate sintered regolith 'far term lunar base' was undertaken. A technique was devised for casting slabs of sintered (basaltic) regolith and assembling these into a hemispherical (or geodesic) dome. The major problem occurs with the inner liner. At 14.7 psi and 20 percent oxygen internal atmosphere, the entire structure is in tension, even with the regolith load. Also, another study has indicated that at 14.7 psi major resupply of air will be needed because of leakage, and astronauts may have to engage in extensive pre-breathing and post-breathing for extravehicular activity (EVA) tasks, thus detracting from useful mission work time. An alternative is to operate part of the base at, say, 5 psi and 70 percent oxygen, or to equip the astronauts with hard suits at 8.3 psi or greater. All of these choices directly influence base design and construction techniques.

Morgenthaler, George W.↗
NASA NTRSDate not supplied

NASA’s Moon-to-Mars Planetary Autonomous Construction Technology Project: Overview and Status

NASA plans to land the first woman and next man on the Moon by 2025 through the initial Artemis missions. NASA and its international partners plan to establish a sustainable long-term presence on the lunar surface and build up infrastructure in the subsequent Artemis missions. The Lunar Surface Innovation Initiative (LSII), within NASA’s Space Technology Mission Directorate, aims to spur the creation of novel technologies needed for lunar surface exploration and accelerate the technology readiness of key systems and components. The primary thrust areas of LSII include sustainable power; dust mitigation; in-situ resource utilization; surface excavation, construction, and outfitting; and extreme access/extreme environments. The Moon-to-Mars Planetary Autonomous Construction Technology (MMPACT) projectwas initiated to address the lunar surface construction thrust area of LSII. The goal of the MMPACT project is to develop, deliver, and demonstrate on-demand capabilities to protect astronauts and create infrastructure on the lunar surface via construction of landing pads, habitats, shelters, roadways, berms and blast shields using lunar regolith-based materials. The MMPACT project is leveraging technology derived from NASA’s 3D Printed Mars Habitat Challenge along with contributions from other Government agencies, and multiple partners within industry and academia. The MMPACT project is comprised of three interrelated elements, construction hardware and process development; feedstock materials development; and microwave structure construction capabilities. These elements are working together to address the multiple challenges of infrastructure construction on the surface of the Moon including increased autonomy of operations, hardware operation and manufacturing under lunar environmental conditions, long-duration operation of mechanisms and parts, scale of construction activities, and material and construction requirements and standards. This presentation will summarize the status of development activities in each of the three elements, including testing of the various candidate materials, preliminary design concepts for future lunar infrastructure elements, and the vision for future technology demonstrations on the lunar surface. These demonstrations, targeting the mid-to-late 2020’s, are expected to enable landing pad construction and habitat construction resulting in commercial capabilities early in the next decade.

lunar infrastructure↗
NASA NTRSDate not supplied

NASA’s Moon-to-Mars Planetary Autonomous Construction Technology Project: Overview and Status

NASA plans to land the first woman and next man on the Moon by 2025 through the initial Artemis missions. NASA and its international partners plan to establish a sustainable long-term presence on the lunar surface and build up infrastructure in the subsequent Artemis missions. The Lunar Surface Innovation Initiative (LSII), within NASA’s Space Technology Mission Directorate, aims to spur the creation of novel technologies needed for lunar surface exploration and accelerate the technology readiness of key systems and components. The primary thrust areas of LSII include sustainable power; dust mitigation; in-situ resource utilization; surface excavation, construction, and outfitting; and extreme access/extreme environments. The Moon-to-Mars Planetary Autonomous Construction Technology (MMPACT) project was initiated to address the lunar surface construction thrust area of LSII. The goal of the MMPACT project is to develop, deliver, and demonstrate on-demand capabilities to protect astronauts and create infrastructure on the lunar surface via construction of landing pads, habitats, shelters, roadways, berms and blast shields using lunar regolith-based materials. The MMPACT project is leveraging technology derived from NASA’s 3D Printed Mars Habitat Challenge along with contributions from other Government agencies, and multiple partners within industry and academia. The MMPACT project is comprised of three interrelated elements, construction hardware and process development; feedstock materials development; and microwave structure construction capabilities. These elements are working together to address the multiple challenges of infrastructure construction on the surface of the Moon including increased autonomy of operations, hardware operation and manufacturing under lunar environmental conditions, long-duration operation of mechanisms and parts, scale of construction activities, and material and construction requirements and standards. This presentation will summarize the status of development activities in each of the three elements, including testing of the various candidate materials, preliminary design concepts for future lunar infrastructure elements, and the vision for future technology demonstrations on the lunar surface. These demonstrations, targeting the mid-to-late 2020’s, are expected to enable landing pad construction and habitat construction resulting in commercial capabilities early in the next decade.

Additive construction, regolith processing, lunar ↗
DOE OSTI2023

Bottleneck Detection in Modular Construction Factories Using Computer Vision

The construction industry is increasingly adopting off-site and modular construction methods due to the advantages offered in terms of safety, quality, and productivity for construction projects. Despite the advantages promised by this method of construction, modular construction factories still rely on manually-intensive work, which can lead to highly variable cycle times. As a result, these factories experience bottlenecks in production that can reduce productivity and cause delays to modular integrated construction projects. To remedy this effect, computer vision-based methods have been proposed to monitor the progress of work in modular construction factories. However, these methods fail to account for changes in the appearance of the modular units during production, they are difficult to adapt to other stations and factories, and they require a significant amount of annotation effort. Due to these drawbacks, this paper proposes a computer vision-based progress monitoring method that is easy to adapt to different stations and factories and relies only on two image annotations per station. In doing so, the Scale-invariant feature transform (SIFT) method is used to identify the presence of modular units at workstations, and the Mask R-CNN deep learning-based method is used to identify active workstations. This information was synthesized using a near real-time data-driven bottleneck identification method suited for assembly lines in modular construction factories. This framework was successfully validated using 420 h of surveillance videos of a production line in a modular construction factory in the U.S., providing 96% accuracy in identifying the occupancy of the workstations and an F-1 Score of 89% in identifying the state of each station on the production line. The extracted active and inactive durations were successfully used via a data-driven bottleneck detection method to detect bottleneck stations inside a modular construction factory. The implementation of this method in factories can lead to continuous and comprehensive monitoring of the production line and prevent delays by timely identification of bottlenecks.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

Prefabricated High-Strength Rebar Systems with High-Performance Concrete for Accelerated Construction of Nuclear Concrete Structures

This project aimed to reduce the field construction times and fabrication costs of reinforced concrete (RC) nuclear structures through the use of: 1) high-strength steel deformed reinforcing bar (rebar); 2) prefabricated high-strength rebar (HSR) assemblies with headed anchorages; and 3) high-strength concrete (HSC). The focus of the project was not to develop new innovations on materials, but rather to fill a major knowledge gap on the effectiveness, code conformity, and viability (i.e., practicality, commercial availability) of existing high-strength materials in nuclear structures, especially in shear walls, their connections/joints, and around penetrations. These advances promote the Nuclear Energy Enabling Technologies Advanced Methods for Manufacturing (NEET-1) goals of accelerating deployment schedules by at least 6 months and reducing component fabrication costs by 20% or more. Toward this vision, the following objectives were identified and completed: Develop limit-benefit and cost-benefit analysis frameworks: The structural and economic limits and benefits of HSR and HSC in nuclear walls were evaluated. Importantly, it was found that modest increases in concrete strength up to 10.0 ksi and rebar yield strength up to 100 ksi result in the most economic designs and improved structural performance (Barbachyn et al., 2017a and Barbachyn et al., 2017b). Also, an industry survey was distributed to determine the cost benefits associated with prefabrication. Importantly, on-site worker-hours are significantly reduced, allowing for significantly accelerated construction schedules (Devine et al. 2018b). Develop an optimization methodology for structural design: An optimization study was deemed not necessary since the trivial solution with maximized use of high-strength materials and prefabrication always resulted in the largest cost and time savings. Instead, the benefits (and limits) of high-strength materials and prefabrication on construction costs and on-site construction time were investigated through a parametric study. Cost-reductions through the use of HSR and HSC were found to be greater than 40%. Also, on-site construction time of nuclear shear walls can be reduced by up to 83% through the use of prefabricated rebar assemblies. Conduct experimental evaluations of nuclear shear walls and wall-foundation joints: A large scale experimental program was completed on shear-critical RC cantilever deep beams. From these experiments, it was demonstrated that increasing rebar yield strength had a greater effect on increasing lateral strength than increasing the concrete compressive strength. Further, using HSR together with HSC resulted in the highest lateral strength and displacement ductility (Devine et al. 2018a). Additionally, large-scale reversed-cyclic lateral load tests were conducted on RC shear walls. It was demonstrated that through the utilization of HSR and HSC, a wall with 55% reduced vertical and horizontal rebar area was able to achieve 91% of the peak lateral strength of a conventional wall using state-of-practice materials with the same geometry. Further, trim reinforcement with headed anchorages around the penetrations proved to be effective. Develop validated numerical simulation models: Numerical modeling was completed in two phases during this project using 3 different finite element software packages. The first phase used existing measured data from previous experimental studies on stocky RC walls to validate simplified predictive models. Models using two different programs were validated based on a database of 38 stocky walls (Barbachyn et al., 2017a). The second phase occurred after experimental testing using a third and more detailed finite element package. Prediction improvements for the initial stiffness, lateral deformations, damage propagation, and failure mechanisms were targeted. The resulting detailed models more accurately predicted the peak lateral strength, initial and secant stiffnesses, lateral deformations, and cracking patterns of the wall test specimens subjected to reversed-cyclic lateral loading as compared to the simplified pretest models. Develop validated design procedures, tools, and criteria: This project evaluated the accuracy of existing closed-form design equations from U.S. building design standards and previous research (Barbachyn et al. 2017a and Devine et al. 2018a). It was shown that the current predictive equations for shear strength capacity need to be revisited as they provide significant scatter and gross overestimates, indicating the potential for unconservative designs. Further, for both the deep beam and shear wall specimens, the numerical models and flexural capacity predictions provided the most accurate strength predictions. Develop cost-effective field construction procedures: To promote the use of prefabricated rebar assemblies, the following construction conditions where prefabrication would be used instead of in-place rebar tying were identified from an industry survey: 1) to save on construction schedule; 2) to improve safety and/or quality control; 3) for areas with heavy rebar congestion; and 4) for structures with significant repetition in rebar layout. All of these conditions directly apply and benefit nuclear construction where construction costs and schedules are extensive, safety and quality are of utmost importance, the reinforcement is extremely dense, and the reinforcement layout is repetitive in many regions of the shear walls. Additionally, an experimental study was conducted to investigate the changes in bar spacing (with respect to code-required rebar spacing and placement tolerances) when a horizontally assembled prefabricated two-dimensional (2D) rebar mat or three-dimensional (3D) rebar cage is lifted (or tripped) to a vertical position. It was found that the bars involved in both the lateral translation of the rebar assemblies (i.e., movement of the assembly in its horizontal position) and the tripping process were most susceptible to large spacing changes, and thus, their positions within the assembly would need to be checked after the placement of the assembly in place within the formwork. Importantly, the spacings of all of the other bars in the assembly were not affected significantly by the lateral translation and tripping process, thereby eliminating the need to recheck their positions within the assembly (Devine et al. 2018b).

36 MATERIALS SCIENCE↗
NASA NTRS1990

In-space construction and dynamics of large space structures

The types of equipment and structures that will be required to construct very large spacecraft in space are discussed. One of the basic issues that must be resolved is the appropriate mix of humans and machines in the construction process. While the use of robots offers the potential for reducing the number of extra-vehicular activity (EVA) hours required for particular construction operations, the availability of humans greatly increases the reliability of complex construction tasks. A hybrid system is described which makes the best use of man and machine to provide a highly reliable and versatile construction approach. Such a system will provide an efficient method for constructing large spacecraft until fully automated, robotic devices can be perfected. Details are given on an extensive ground test program which was designed to evaluate and demonstrate large spacecraft construction. A discussion is presented on the use of the Space Station Freedom, or an appropriate derivative, as a construction facility. Finally, a construction scenario and assembly timelines are presented for constructing a 20-meter-diameter high precision reflector.

Mikulas, Martin M., Jr.↗
DOE OSTI2018

A comparative method of air emission impact assessment for building construction activities

Highlights: • Impact assessment comparisons for various construction activities are presented. • Impacts of activities are compared from global, regional and local perspectives. • Excavation related activities have the highest POFP impact contributions at local level. • Material related activities have the highest GWP contribution. - Abstract: Different construction activities may indicate distinct environmental impacts due to their uniqueness. Ability to assess and compare the environmental impacts from different construction activities can aid the process of minimising emissions at different building construction processes. The study presents a comparative impact assessment methodology to evaluate environmental impacts at different activities during the building construction stage. Significant impact related construction activities for five major impact categories namely global warming potential (GWP 100), acidification potential (AP), Eutrophication potential (EP), Photochemical oxidation formation potential (POFP) and Human toxicity potential (HTP) are compared from the global, regional and local perspectives. A case study of a residential building in Australia is used to demonstrate the application of the functions of the developed method. The results of the case study indicated that the method can be effectively used to compare environmental impacts of different construction activities at different geographical perspectives considered. The method can be used by designers and contractors in comparing impacts of various construction activities to identify the most emission effective construction processes.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

Functional and structural similarity of human DNA primase [4Fe4S] cluster domain constructs

The regulatory subunit of human DNA primase has a C-terminal domain (p58C) that contains a [4Fe4S] cluster and binds DNA. Previous electrochemical analysis of a p58C construct revealed that its affinity for DNA is sensitive to the redox state of the [4Fe4S] cluster. Concerns about the validity of this conclusion have been raised, based in part on differences in X-ray crystal structures of the p58C 272-464 construct used for that study and that of a N-terminally shifted p58C 266-456 construct and consequently, an assumption that p58C 272-464 has abnormal physical and functional properties. To address this controversy, a new p58C 266-464 construct containing all residues was crystallized under the conditions previously used for crystallizing p58C 272-464 , and the solution structures of both constructs were assessed using circular dichroism and NMR spectroscopy. In the new crystal structure, p58C 266-464 exhibits the same elements of secondary structure near the DNA binding site as observed in the crystal structure of p58C 272-464 . Moreover, in solution, circular dichroism and 15 N, 1 H-heteronuclear single quantum coherence (HSQC) NMR spectra show there are no significant differences in the distribution of secondary structures or in the tertiary structure or the two constructs. To validate that the two constructs have the same functional properties, binding of a primed DNA template was measured using a fluorescence-based DNA binding assay, and the affinities for this substrate were the same (3.4 ± 0.5 μM and 2.7 ± 0.3 μM, respectively). The electrochemical properties of p58C 266-464 were also measured and this p58C construct was able to engage in redox switching on DNA with the same efficiency as p58C 272-464 . Together, these results show that although p58C can be stabilized in different conformations in the crystalline state, in solution there is effectively no difference in the structure and functional properties of p58C constructs of different lengths.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Assessment of small mechanical wastewater treatment plants: Relative life cycle environmental impacts of construction and operations

Many slow growing and shrinking rural communities struggle with aging or inadequate wastewater treatment plants (WWTPs), and face challenges in constructing and operating such facilities. Although existing literature has provided insight into the environmental sustainability of large facilities, including both the construction and operational phases, these studies have not examined small, rural facilities treating less than 7,000 m 3 /d (1.8 MGD) of wastewater in adequate depth and breadth. In this study, a detailed inventory of the construction and operational data for 16 case studies of small WWTPs was developed to elucidate their environmental life cycle impacts. Conventional LCA framework was followed. The results show that the environmental impacts of both the construction and operational phases are considerable. Operational impacts are highly related to energy usage. Improving energy efficiency of a plant may reduce the environmental impacts related to operations. Construction impacts can vary considerably between facilities. Process-related factors (e.g., concrete and reinforcing steel used in basins) are typically sized using the design flow; thus much of the variability in construction impacts among plants stems from the non-process related infrastructure. Multiple regression analysis was used as an exploratory tool to identify which non-process related plant aspects contribute to the variable environmental impact of small WWTPs. These factors include aluminum, cast iron, and the capacity utilization ratio (defined as the ratio of average flow to design flow). Furthermore, industry practitioners should consider these factors when aiming to reduce the environmental impacts of a small WWTP related to construction. Scenario sensitivity analyses found that the environmental impact of construction became smaller with longer design life, and the end-of-life consideration does not heavily influence the environmental sustainability of a WWTP.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

Simulation of wellbore construction in offshore unconsolidated methane hydrate-bearing formation

The unconsolidated nature of offshore methane hydrate-bearing formation poses concerns for sustainable methane gas production as the weak formation is susceptible to disturbance during wellbore construction. Furthermore, this could contribute to loss of well integrity which could manifest as sand production and error in the interpretation of downhole tests such as mini-frac tests. In this study, a simulation methodology of wellbore construction process is proposed. A finite element model adopting this methodology is developed in order to assess the effect of wellbore construction process on the integrity of the unconsolidated methane hydrate-bearing formation in the Nankai Trough, Japan. The primary objectives are (i) to develop a modelling methodology of well construction process for numerical simulations, (ii) to assess the zone and magnitude of well construction-induced stress/strain disturbance in the formation and (iii) to evaluate relative impact of each well construction stage on the integrity of the formation. The results from this study show that the zone of horizontal stress disturbance from the geostatic state due to wellbore construction could extend to more than three times the radius of the wellbore. Following the wellbore construction, the deviator stress is concentrated in the hydrate reservoir sublayers with high hydrate saturation while plastic deviatoric strain has accumulated in the sublayers with low hydrate saturation. The results also show that modelling of cement shrinkage process is crucial in predicting the concentration of deviator stress in the high hydrate saturation layers.

03 NATURAL GAS↗
NASA NTRS1989

Addressing the problem of interruptability in the construction of large space structures

Large scale space missions of the near future will depend upon successful multi-launch coordination and construction in the space environment. One of the main challenges is how to accomplish a valid global analysis of a construction project with the intent of improving safety, reducing overall mission cost, and total construction time. These three items are dependent on the interruptability of the project, which is the ability of the project to recover from unplanned interruptions; such as failure of the launch vehicle; sudden, on-orbit, crew illness; or damage from a space debris impact on the partially completed space structure. A new method for addressing and analyzing this type of problem is being developed. The method is called Program Interruptability and Risk Evaluation Technique, or PIRET. PIRET has been developed in order to model and analyze potential interruptability concerns of the construction of the U.S. Space Station Freedom (SSF), although PIRET is applicable to any complex, multi-launch structural assembly. This paper is a progress report on the continuing research of the NASA Center for Space Construction at the University of Colorado, Boulder into this area of space construction interruptability. The paper will define the problem of interruptability, will diagram the PIRET approach to space construction, will share results from a preliminary PIRET analysis of SSF, and will show that PIRET is a useful tool for modelling space construction interruptability.

Davidson, Roger A.↗
DOE OSTI2019

Metal accumulation in dragonfly nymphs and crayfish as indicators of constructed wetland effectiveness

Constructed wetland effectiveness is often assessed by measuring reductions of contaminant concentrations in influent versus departing effluent, but this can be complicated by fluctuations in contaminant content/chemistry and hydrology. We assessed effectiveness of a constructed wetland at protecting downstream biota from accumulating elevated metal concentrations—particularly copper and zinc in effluents from a nuclear materials processing facility. Contaminants distributed throughout a constructed wetland system and two reference wetlands were assessed using six dragonfly nymph genera (Anax, Erythemis, Libellula, Pachydiplax, Tramea, and Plathemis) as biomonitors. Additionally, the crayfish, Cambarus latimanus, were analyzed from the receiving and two reference streams. Concentrations of Cu, Zn, Pb, Mn, Cr, Cd, and Al were evaluated in 597 dragonfly nymph and 149 crayfish whole-body composite samples. Dragonfly genera varied substantially in metal accumulation and the ability to identify elevated metal levels throughout components of the constructed wetland. Genera more closely associated with bottom sediments tended to accumulate higher levels of metals with Libellula, Pachydiplax, and Erythemis often accumulating highest concentrations and differing most among sites. This, combined with their abundance and broad distributions make the latter two species suitable candidates as biomonitors for constructed wetlands. As expected, dragonfly nymphs accumulated higher metal concentrations in the constructed wetland than reference sites. However, dragonfly nymphs often accumulated as high of metal concentrations downstream as upstream of the water treatment cells. Moreover, crayfish from the receiving stream near the constructed wetland accumulated substantially higher Cu concentrations than from downstream locations or reference streams. Despite reducing metal concentrations at base flow and maintaining regulatory compliance, metal fluxes from the wetland were sufficient to increase accumulation in downstream biota. Future work should evaluate the causes of downstream accumulation as the next step necessary to develop plans to improve the metal sequestering efficiency of the wetland under variable flow regimes.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗
DOE OSTI2018

Wind Energy and Wildlife Pre- and Post-Construction Project at Pantex Plant

From 2009-2017, we conducted pre- and post-construction monitoring of wildlife at the Pantex Plant before and after construction of five wind turbines on the plant in 2014-2015. Pre-construction acoustic monitoring for bats was conducted at five sites on Pantex. Acoustic (here after Anabat) files were downloaded 30 times with Anabat files recorded from 6/21/2010 through 1/17/2014. The resulting data include over 3,000,000 files and we hope to analyze them in the future. We were never successful recording acoustic data after 2014 (post-construction). This is despite numerous attempts to trouble shoot our acoustic monitors. Wind damage to cables going from the body of the monitor to their microphones could not be repaired or replaced while towers were standing. Sampling of breeding birds was accomplished through point counts conducted at sites selected for turbine construction and others selected as control sites. Precipitation varied greatly over the course of the study, from a low of 17.81 cm (7.01 inches) during 2011 to a high of 87.96 cm (34.63 inches) during 2015. The pre-construction portion of the project was characterized by fairly extreme drought starting in 2011. Total precipitation for 2011 and 2012 was just 49.12 cm (19.34 inches), less than 50% of the average for a two-year period. The impact of this drought on nesting grassland birds manifest as low nesting species richness and abundance. In 2011 and 2012, 20 and 17 species were documented during point counts, respectively. Post-construction sampling followed the wet year of 2015 (87.96 cm, 34.63 inches). Species richness of nesting birds in 2016 and 2017 was considerably higher than during the drought, 40 and 37 species, respectively. We suspect changes in resource availability associated with relief from drought starting after 2015 was responsible for the recovery/increase in species detected during the breeding season; less importantly any changes from installation of turbines or changes in surface management (e.g., row-crop type).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Heating and Cooling Energy Modeling of 3D-Printed Concrete Construction of Residential Buildings [Slides]

3D printed concrete construction (C3DP) is an emerging technology that comes with the associated benefits of high thermal mass walls. We investigated using BEopt software the heating and cooling energy use of a single story C3DP-constructed house. We then compared the heating/cooling energy use of the C3DP house against the corresponding energy use in a traditional timber (wood) frame construction (WFC), as well as a concrete masonry unit (CMU) construction. Both peak energy use for heating and cooling (Btu), as well as base energy use for both heating and cooling (MMBtu/yr) of the C3DP design were compared against the WFC and CMU baseline construction of identical geometries and orientations across all eight climate zones defined in the International Energy Conservation Code (IECC). The BEopt models for all three constructions (C3DP, WFC, and CMU) were built to comply with the 2018 IECC code. Results indicate that C3DP construction has significant heating and cooling energy benefits in certain climate zones, with the highest peak cooling energy savings (9% compared to WFC, and 5% compared to CMU) in the IECC Climate Zone 1 in the month of July. The peak heating and cooling energy demand reduction of C3DP were found to be more significant than the base heating and cooling energy demand in all IECC climate zones. The 2018 IECC compliance-related U-Factor adjustments of all models also resulted in more peak energy savings of the C3DP design in the cooling-dominated climate zones (climate zones 1 and 2), moderate energy savings in moderate climate zones (climate zones 3, 4, and 6), and little to no change in energy savings in very cold climates (climate zones 7 and 8).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Automated Progress Monitoring in Modular Construction Factories Using Computer Vision and Building Information Modeling

Modular construction methods have recently gained interest due to the advantages offered in terms of safety, quality, and productivity for projects. In this method, a significant portion of the construction is performed off-site in factories where modular components are built in different workstations, assembled on the production line, and shipped to the site for installation. Due to the labor-intensive nature of tasks, cycle times in modular construction factories are highly variable, which commonly leads to major bottlenecks and delays in construction projects. To remedy this effect, recent methods rely on sensors such as RFID to monitor the production process, which is reportedly expensive, and intrusive to the work process. Recently, computer vision-based methods have been proposed to track the production process in modular construction factories. However, these methods overlook monitoring the assembly process on the production line. Therefore, this paper presents a method to monitor the assembly process by integrating computer vision-based methods with Building Information Modeling (BIM). The proposed method detects the modular units using object segmentation; superimposes the installation area with the corresponding 2D region using BIM, and identifies the installation of the components using image processing techniques. The proposed method has been validated using surveillance videos captured from a modular construction factory in the US. Successful implementation of the proposed method can lead to timely identification of delays during the assembly process and reduce delays in modular integrated construction projects.

building information modeling↗
DOE OSTI2020

A Path to Zero Energy Ready Home Construction

This paper will be presented at the 5th Residential Building Design & Construction Conference in State College, Pennsylvania. While the number of zero energy homes constructed in the U.S. has grown dramatically, increasing nearly 400% since 2015, zero energy homes still accounted for less than 1% of all U.S. homes constructed as of December 2018. Concerns about high costs or implementation challenges have kept many builders from attempting zero energy home construction. However, builders participating in the U.S. Department of Energy’s Zero Energy Ready Home Program are showing that zero energy ready home construction can be achieved simply and cost effectively with off-the-shelf equipment and materials and common construction techniques. Construction methods used by builders in the DOE program are compared with those used in just-to-code new homes and existing homes for several key components, including wall assemblies and HVAC systems. Examples of cost-effective assemblies used in the Mid Atlantic states are provided.

U.S. Department of Energy Building Technologies Pr↗
DOE OSTI2022

Enhancing Worker Safety During Off-Site Construction of Energy-Efficient, Low-Carbon Exterior Envelope

The construction industry is not doing enough to embrace off-site modular construction. It is a missed opportunity for optimized energy efficiency because prefabricated exterior wall envelopes are lower in cost and faster and easier to install. Factory off-site construction offers improved safety for construction workers because work is done in a controlled environment, but lack of intent, understanding, and data is also a missed opportunity for enhancing worker safety. This research looks specifically at the prefabricated wall exterior envelope in the context of safety. The research question is "off-site factories build with ease of energy efficiency and lowered carbon emissions, but is the process safer?" This research was funded by NREL Student Training in Applied Research (STAR) program, University Partnerships Program, and Wells Fargo Bank. Key finding is that modular and prefabricated construction are perceived to be safer, but the accident rates are much higher than in the general construction and manufacturing industries. Proposed solutions to decrease accidents in off-site prefabricated construction includes safety training for workers, provide movable kiosks with PPE at workstations, ensure tools are well-maintained and place safety posters in visible locations. Future work includes improving worker safety to increase worker productivity, perform pilot demonstration, work with factory designers for new modular layout for worker safety, i.e., easy access to PPE kiosks, and work closely with OSHA so that they take notice of this safety niche.

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