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"In 2017, it was all about whether we could print a building that size," says Kreiger. Marines are the builders of both prototypes. One is to build on the ERDC 3D-printed concrete barracks research, completed last year on a hut of the same size but with a different design.
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The research, conducted at the Corps' Construction Engineering Research Laboratory in Champaign, Ill., has several other goals. SOM had the awareness and just needed to go from the polymer to concrete." "We were looking for an engineer that had the fundamentals down. "3D-printed structures require a different mindset about how the building is constructed," says Megan Kreiger, ACES project manager. of Energy, using a carbon-fiber-reinforced acrylonitrile butadiene styrene thermoplastic material. SOM signed on because it had designed a 3D-printed project for the Dept. A report, with design guidelines, will follow in a few months.įor the engineering, ERDC engaged the Chicago office of Skidmore, Owings & Merrill LLC. The precast concrete roof should be done by the end of September. The primary goal of the 3-D printed concrete barracks project, ERDC's second, is to determine "what it would take for a structural engineer to sign off on the B-hut for permitting," says Case.Ĭonstruction of the walls is complete. The technology also reduces the resources needed and logistics associated with material shipments for wood-framed barracks. Once all kinks are ironed out, a trained crew of three per shift will be needed to build the "B-hut," instead of eight for a conventional barracks, according to ERDC. With continuous printing executed in two or three shifts, construction time is potentially one day instead of five for a wood-framed barracks. Materials for the barracks, expected to be completed next month, cost $6,000.ĪCES is developing a technology capable of 3D-printing custom-designed expeditionary structures on demand, in the field, using concrete sourced from local materials. and NASA's Marshall Space Flight Center and Kennedy Space Center. Marine Corps, with support from Caterpillar Inc. Army Engineer Research and Development Center.ĪCES is funded by about $250,000 from the U.S. "To our knowledge, before us, no one has done the structural testing to show they are safe," which is the main reason why there are no 3D-printed concrete barracks in use, says Michael Case, the program manager for the project, called Automated Construction of Expeditionary Structures (ACES), which is within the U.S. The current research is considered the first to "definitively" demonstrate through full-scale prototype testing that a 3D-printed concrete barracks with a precast roof can be engineered to be structurally safe for occupancy. of Engineers' researchers, leading a team that recently completed the 3D printing of 9.5-ft-tall reinforced concrete walls for a 32-ft x 16-ft barracks, are setting their sights on a future project-3D printing of concrete roof beams-even before they put the precast concrete lid on the printed walls.