Automated Construction of Expeditionary Structures (ACES) : Materials and Testing

Complex military operations often result in U.S. forces remaining at deployed locations for long periods. In such cases, more sustaina-ble facilities are required to better accommodate and protect forward-deployed forces. Current efforts to develop safer, more sustaina-ble operating facilities for contingency bases involve construction activities that require a redesign of the types and characteristics of the structures constructed, that reduce the resources required to build, and that decrease the resources needed to operate and maintain the completed facilities. The Automated Construction of Expeditionary Structures (ACES) project was undertaken to develop the capa-bility to “print” custom-designed expeditionary structures on demand, in the field, using locally available materials with the minimum number of personnel. This work investigated large-scale automated “additive construction” (i.e., 3D printing with concrete) for con-struction applications. This report, which documents ACES materials and testing, is one of four technical reports, each of which details a major area of the ACES research project, its research processes, and its associated results. There major areas include System Require-ments, Construction, and Performance; Energy and Modeling; Materials and Testing; Architectural and Structural Analysis.