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All sourcesNASA NTRSDOE OSTI
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 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.

drywall↗
DOE OSTI2021

Decarbonization During Predevelopment of Modular Building Solutions

Off-site construction methods offer the opportunity to compress costs of net-zero energy (NZE) housing using the advantages of mass production. There has been limited investigation on trade-offs between site-built and industrialized construction from the perspective of reducing the incremental cost of NZE strategies and reducing greenhouse gas emissions during embodied and operational stages. Blokable, LLC, a vertically integrated modular builder, wanted to know how the learning curves of mass production would help them decarbonize their existing modular housing prototype at a relative cost advantage. The method developed for this question looked at the life cycle assessment of an individual apartment and used learning-curve efficiencies to approximate the relative advantage of construction-at-scale. Greenhouse gas emissions were quantified by a learning-affected, whole-life carbon emissions model and demonstrated a path to a 60% reduction of whole-life CO2-equivalent in the 2030 production year. The resultant roadmap considers a best-first approach to decarbonizing a modular building product line, and the method can be replicated for other modular builders.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Optimized Floating Offshore Wind Turbine Substructure Design Trends for 10–30 MW Turbines in Low-, Medium-, and High-Severity Wave Environments

Floating offshore wind is a promising renewable energy source, as 60% of the wind resources globally are found at depths requiring floating technologies, it minimizes construction at sea, and provides opportunities for industrialization given a lower site dependency. While floating offshore wind has numerous advantages, a current obstacle is its cost in comparison to more established energy sources. One cost-reduction approach for floating wind is increasing turbine capacities, which minimizes the amount of foundations, moorings, cables, and O&M equipment. This work presents trends in mass-optimized VolturnUS hull designs as turbine capacity increases for various wave environments. To do this, a novel rapid hull optimization framework is presented that employs frequency domain modeling, estimations of statistical extreme responses, industry constructability requirements, and genetic algorithm optimization to generate preliminary mass-optimal VolturnUS hull designs for a given turbine design and set of site conditions. Using this framework, mass-optimized VolturnUS hull designs were generated for 10–30 MW turbines for wave environments of varying severities. These design studies show that scaling up turbine capacities increases the mass efficiency of substructure designs, with decreasing returns, throughout the examined turbine capacity range. Additionally, increased wave environment severity is shown to increase the required mass of a given substructure design.

VolturnUS↗
DOE OSTI2024

Component pose reconstruction using a single robotic total station for panelized building envelopes

The construction industry can benefit greatly from increased automation in construction processes in terms of precision, time, and labor costs. This is especially true for prefabricated construction for either new buildings or envelope retrofits. Here, prefabricated components are manufactured offsite according to design specifications and installed onsite. Accurate information on the component’s position and orientation (pose) is needed to achieve this. A tool named “Real-Time Evaluator” (RTE), designed to autonomously track prefabricated components as they are being installed and provide real-time installation instructions, is currently under development using a single robotic total station. This is challenging since at least three points are needed to determine the pose of an object in space. To achieve this goal with a single robotic total station, two key algorithms were developed: the “resection” algorithm aligns the digital twin with the physical twin regardless of the location of the total station, and the “transformation” algorithm gives instructions of translations and rotations to installers to achieve the desired installation pose. The algorithms were evaluated experimentally on a lab-scale demonstration. Results show that the resection algorithm achieved an average error of < 3.1 mm, while the transformation algorithm predicted the rotation angle along a single axis with an error of < 0.5◦.

Tang, Mengjia↗
DOE OSTI2022

2020 Solar Decathlon Education Partner: Cooperative Research and Development (Final Report, CRADA Number CRD-19-00802)

The U.S. Department of Energy Solar Decathlon (DOE/SD) is a collegiate competition, comprising 10 contests, that challenges student teams to design and build highly efficient and innovative buildings powered by renewable energy. The winners will be those teams that best blend architectural and engineering excellence with innovation, market potential, building efficiency, and smart energy production. The DOE/SD is comprised of two Challenges--Design Challenge (annual, in April of each year at NREL in Golden, Colo.) and Build Challenge (biennial, held next in June/July 2020 in Washington D.C.). NREL provides competition management for DOE/SD. For over 35 years, EEBA has provided the most trusted resources for building science information and education in the construction industry. EEBA delivers turn-key educational resources and events designed to transform residential construction practices through high performance design, marketing, materials, and technologies. NREL and EEBA establish this CRADA to enable the success of the DOE/SD program in managing sponsorship funds and creating a professional education program. EEBA acted as an Education Partner to DOE/SD, which included: 1) accepting and dispersing sponsorship funds for DOE/SD; and 2) providing professional development content.

14 SOLAR ENERGY↗
DOE OSTI2022

Experimental validation of multiphysics model simulations of the thermal response of a cement clinker rotary kiln at laboratory scale

Abstract An increasing demand for buildings, transportation systems and civil infrastructure development has driven expansion of cement consumption world‐wide, producing a significant increase in related global energy demand. With approximately 7% of the world‐wide industrial energy consumption (10.7 exajoules [EJ]), the cement industry is the third most energy intensive industrial processes and a key component for concrete, the most consumed composite material in the global construction industry. In cement manufacturing, the cement kiln accounts for most of the energy consumption in the production process. As the heart of a cement plant, the cement kiln is where the kiln feed primarily containing calcium oxide (CaO), silica (SiO 2 ), alumina (Al 2 O 3 ), and iron (Fe 2 O 3 ) are thermally and chemically transformed into clinker minerals. The presented work developed a multiphysics model, designed and built a laboratory‐scale rotary cement clinker kiln, and produced cement clinker at laboratory‐scale. The model was developed to study the interaction between the various thermal, fluid dynamic and chemical interactions involved in the sintering process used to form Portland cement clinker in an effort to reduce energy use. The analytical model was validated through experimental testing using a unique laboratory‐scale rotary cement kiln developed during the investigation. Also demonstrated was the feasibility of producing clinker at laboratory scale. This modeling and lab scale tests were designed to better understand the clinker sintering process so that operational and quality decisions can be made to optimize energy consumption without compromising cement clinker quality. The computational fluid dynamics modeling was developed in COMSOL Multiphysics 6.0. The characteristics of the combustion fluid flow, concentration of species, temperature and heat transfer were studied for a turbulent flow of methane (CH 4 ) gas and oxygen (O 2 ). Theory suggests that heat transfer impacts the cement production process but the multiphysics model more accurately describes the convection, conduction, and radiant heat transfer in the kilning process and thus allows for a better understanding of the energy exchange driving the chemical reactions that produce Portland cement. Clinker minerals were formed because of appropriate burning conditions implemented during experimental model validation.

Tabares, Juan David↗
DOE OSTI2025

Integration of a real-time orientation measurement system for a real-time evaluator (RTE) to measure the position and orientation of crane-lifted components

Prefabrication of building components holds the potential to revolutionize the construction industry. Prefabrication consists of manufacturing building components, modules, and other elements in a factory to be shipped and installed on a construction site. Prefabricated components have been produced for various applications including precast concrete panels for new construction and exterior wall retrofits. The manufacturing process has seen much innovation in recent years; however, the installation process has seen minimal advancements. A real-time evaluator (RTE) was developed to reduce the installation cost of prefabricated components by reducing installation time, decreasing rework, and improving accuracy. The RTE uses off-the-shelf hardware and novel algorithms to assist erectors with component installation by measuring the real-time positions of connections and prefabricated components, providing installation guidance through a graphical user interface, and monitoring the accumulated installation errors. An overview of the RTE and the proposed workflow is presented. Previous on-site demonstrations provided valuable feedback from users on the potential areas for improvement of the system. One common request was real-time measurement of component orientation during lifting, a process that previously required that the component remain stationary while the laser tracker cycled through target prisms. This paper will present the incorporation and testing of a real-time orientation measurement system as it was implemented into the RTE, allowing for measurement of component orientation during movement.

Selvakumar, Balaji [ORNL]↗
DOE OSTI2025

Demand Response in Residential Energy Code: Technical Brief

As buildings account for over 75% of U.S. electricity use, effectively managing their loads can greatly facilitate the transition towards a clean, reliable grid. Grid-interactive efficient buildings (GEBs) combine efficiency and demand flexibility with smart technologies and communication to provide occupant comfort and productivity while serving the grid as a distributed energy resource (DER). In turn, GEBs can play a key role in ensuring access to an affordable, reliable, sustainable, and modern U.S. electric power system. Their national adoption could provide $\$$100-200 billion in U.S. electric power system cost savings over the next two decades. The associated reduction in CO 2 emissions is estimated at 6% per year by 2030 (DOE 2021). Building codes represent standard design practice in the construction industry and continually evolve to include advanced technologies and innovative practices. Historically, national model energy codes establish minimum efficiency requirements for new construction (ICC 2020). Expanding codes to support GEB capabilities is a pivotal step towards realizing demand flexibility in support of a clean grid by addressing capabilities to improve interoperability between smart building systems, the grid, and renewable energy resources. Realizing GEBs requires buildings with automated demand response (DR) capabilities that enable standardized communication with or control of, subject to explicit consumer consent, energy smart appliances or home energy management systems. This is achieved through direct or indirect (i.e., via an aggregator) communication between appliances and the electric grid. Energy codes can also support DR communication standardization and advance the deployment of building-integrated DERs such as energy storage, generation, and electric vehicles (EVs). Incorporating automated DR capabilities in energy codes provides many benefits to the consumers. Specifically, it aligns building electric load demand with intermittent renewable energy source availability, decreases peak load on the electric grid, allows buildings to respond to utility price signals, supports electrical network reliability and market growth of products and processes aligned with clean economic growth. The incorporation of DR into the model residential energy codes was considered for both the 2021 and 2024 International Energy Conservation Code (IECC) code development cycles. The approved DR measures in the 2021 cycle were removed in response to appeals (ICC 2020). Updated language was presented for consideration again for the 2024 IECC, where it was negotiated and again approved, and again removed in response to appeals (ICC 2024). This resulted in many sections, including sections on demand responsive controls, being moved to the credits options or an appendix as a voluntary application. This technical brief updates the proposed DR components such that they can be considered by states and local governments for direct incorporation into their codes, as well as for future IECC energy code development. The proposal refinements are intended to support consistency in approach and provide a degree of certainty for building owners, designers, contractors, manufacturers, and building and fire safety professionals. The scope of this technical brief includes three strategies for DR in residential buildings: 1) smart thermostats with demand-responsive control, 2) electric water heating incorporating demand-responsive controls and communication and 3) grid Integrated solar and energy storage systems.

2021 IECC↗
DOE OSTI2026

Force-triggered, Bio-based, Sealants for Prefabricated Building Components: Towards Improved Efficiency, Performance and Sustainability

The prefabricated building construction industry has made extensive progress in expediting the manufacture of prefabricated components at offsite plants. However, this progress has not translated to the assembly of the prefabricated components at the construction site. Case in point, sealing the joints between components to prevent air leaks requires the manual application of tape, caulk, or spray foam at the jobsite, and performance is highly dependent on the skills of the installer. To reduce assembly time and improve the airtightness and waterproofness of prefabricated components, we developed a sealant that can be installed at the plant and have its curing reaction triggered at the jobsite. Additionally, we used this opportunity to explore the use of bio-based feedstocks that are abundant and not used for food. We evaluated a series of force-triggered, bio-based, high strength, and fast curing sealants, consisting of a one-part heterogeneous system. These sealants are derived from formulations with ≥80% of bio-based components, consisting of a cardanol derived diepoxy that is microencapsulated in a polymer shell and embedded in a cardanol derived amine curing agent. The microcapsule shell allows separation of the reactive species in the one-part sealant allowing a fast-curing system to remain unreacted until the right trigger is applied. When the microcapsules are activated and broken by force, the highly reactive species mix and cure, exhibiting peel strengths up to 143 ppi. The open-air shelf stability of the sealant complexes was demonstrated by peel strength values of ~16 ppi when triggering the curing reaction even after being exposed for 8 months to open air and humidity. The successful on-demand triggering of curing reactions and the shelf stability provide efficacy of these force-triggered sealants for installation on prefabricated components, storage for months prior to delivery, and assembly at the jobsite. These force-triggered bio-based sealants for prefabricated buildings could result in lower installation time and cost as well as better performance than tapes and caulks at the jobsite.

Cortes Guzman, Karen [ORNL] (ORCID:000000028793468↗
DOE OSTI2026

Robotics for Energy Infrastructure Construction on Earth and Beyond: Pilot Study Exploring Level 3-4 Semi-Autonomous Installation of a Reduced-Scale Photovoltaic Power Plant Prototype: Preprint

There is a growing need to build energy infrastructure at massive scale on both Earth and in space. On Earth, increasing electricity demand from applications such as AI data centers is driving rapid expansion of power systems, while in space, long-duration missions such as lunar operations require reliable and resilient energy infrastructure that can be deployed quickly. These needs outpace the capabilities of conventional construction methods. Robotic construction offers a path to faster, lower-cost, and more consistent deployment, yet most existing approaches focus on automating individual tasks rather than end-to-end assembly. The Industrialized Construction Innovation (ICI) team at the National Laboratory of the Rockies (NLR), in collaboration with the Colorado School of Mines, has been investigating robotics and automation strategies for rapid end-to-end energy infrastructure construction. This paper presents a pilot study demonstrating level 3-4 semi-autonomous, end-to-end robotic assembly of a reduced-scale photovoltaic power plant prototype under terrestrial conditions. The approach combines hardware redesign of photovoltaic components for robotic compatibility, discrete-event and physics-based robotic simulations in synthetic environments, and sim-to-real deployment to execute end-to-end robotic assembly of[NM1.1][NM1.2] tracking components, structural members, photovoltaic modules, and embedded electrical connections. The pilot identifies key limitations like tolerance management, perception and localization, end effector capability, fastening methods, and multi-physics simulation fidelity, that must be addressed to enable end-to-end robotic assembly of full-scale energy infrastructure. The study highlights how these insights inform scaling strategies for terrestrial energy infrastructure and adaptation to unstructured and extreme environments, including off-world scenarios such as robotic assembly of vertical tall lunar towers.

14 SOLAR ENERGY↗
DOE OSTI2026

Force-triggered, Bio-based, Sealants for Prefabricated Building Components: Towards Improved Efficiency, Performance and Sustainability

The prefabricated building construction industry has made extensive progress in expediting the manufacture of prefabricated components at offsite plants. However, this progress has not translated to the assembly of the prefabricated components at the construction site. Case in point, sealing the joints between components to prevent air leaks requires the manual application of tape, caulk, or spray foam at the jobsite, and performance is highly dependent on the skills of the installer. To reduce assembly time and improve assembly quality of prefabricated components, we developed a sealant that can be installed at the plant and triggered at the jobsite. Additionally, we used this opportunity to lower the use of fossil fuel derived feedstocks and introduced bio-based alternatives to decrease the embodied carbon of the new sealant. We evaluated a series of force-triggered, bio-based, high strength, and fast curing sealants, consisting of a one-part heterogeneous system. These sealants are derived from formulations with ≥80% of biogenic carbon, consisting of a cardanol derived diepoxy that is microencapsulated in a polymer shell and embedded in a cardanol derived amine curing agent. The microcapsule shell allows separation of the reactive species in the one part sealant allowing shelf stability to an otherwise fast curing system. When the microcapsules are broken and activated by force, the highly reactive species mix and cure, exhibiting peel strengths up to 143 ppi. The shelf stability of these sealants and the on-demand triggering of the curing reactions enable installation on prefabricated components and storage prior to delivery and assembly at a jobsite, which could result in consistent sealant application with lower installation time than tapes and caulks at the construction site.

Cortes Guzman, Karen [ORNL] (ORCID:000000028793468↗
DOE OSTI2020

Lung cancer mortality among construction workers: implications for early detection

Objectives This study examined predictors of lung cancer mortality, beyond age and smoking, among construction workers employed at US Department of Energy (DOE) sites to better define eligibility for low-dose CT (LDCT) lung cancer screening. Methods Predictive models were based on 17 069 workers and 352 lung cancer deaths. Risk factors included age, gender, race/ethnicity, cigarette smoking, years of trade or DOE work, body mass index (BMI), chest X-ray results, spirometry results, respiratory symptoms, beryllium sensitisation and personal history of cancer. Competing risk Cox models were used to obtain HRs and to predict 5-year risks. Results Factors beyond age and smoking included in the final predictive model were chest X-ray changes, abnormal lung function, chronic obstructive pulmonary disease (COPD), respiratory symptoms, BMI, personal history of cancer and having worked 5 or more years at a DOE site or in construction. Risk-based LDCT eligibility demonstrated improved sensitivity, specificity and positive predictive value compared with current US Preventive Services Task Force guidelines. The risk of lung cancer death from 5 years of work in the construction industry or at a DOE site was comparable with the risk from a personal cancer history, a family history of cancer or a diagnosis of COPD. LDCT eligibility criteria used for DOE construction workers, which includes factors beyond age and smoking, identified 86% of participants who eventually would die from lung cancer compared with 51% based on age and smoking alone. Conclusions Results support inclusion of risk from occupational exposures and non-malignant respiratory clinical findings in LDCT clinical guidelines.

Public, Environmental & Occupational Health↗
DOE OSTI2024

Electrochemically Enhanced Carbonate Precipitation into Building Materials: A Scalable Carbon Sequestration Strategy

Decarbonization goals across hard-to-abate industries have prompted an urgent need for advanced carbon capture and storage technologies. Sequestering CO2 into carbonate minerals is a scalable method of carbon management with the ability to produce value-added carbon negative materials from waste streams for the construction industry. Waste streams rich in Ca and Mg such as nickel mine tailings, iron/steel slag, and reverse osmosis brines can store 7.6 Mt CO2/year as minerals. Additionally, CO2 mineralization in acid-neutralization processes currently present in industrial waste treatment can eliminate associated CO2 emissions of lime processing by improving process circularity. The carbonate minerals formed from these waste sources are valuable as components of carbon-negative concrete, which have the potential to sequester 1.8 billion Mt of CO2/year. Electrochemical means of CO2 mineralization improves the kinetics of the thermodynamically favorable mineralization process, lessening or eliminating the high energy requirements of traditional methods. Here, we investigate benchtop scale electrochemical CO2 mineralization of alkaline mining waste, highlighting the effects of key constituents in mining waste on the mineralization process.

carbon capture↗
DOE OSTI2025

Cement and concrete as carbon sinks: Transforming a climate challenge into a carbon storage opportunity

Cement and concrete, while traditionally recognized as the main contributors to anthropogenic CO 2 emissions, also have untapped capacity to serve as substantial and scalable carbon sinks. This perspective examines how engineered mineral carbonation can transform cement-based materials into functional carbon storage systems, generating both environmental and economic value. We review the fundamental mechanisms of CO 2 uptake in cementitious systems, highlighting current limitations in reaction kinetics, phase control, and durability under varying environmental conditions. Emphasis is placed on the utilization of alkaline industrial residues and emerging magnesium-based cements, which offer synergistic pathways for carbon sequestration and circular resource use. We further assess the performance trade-offs associated with CO 2 uptake and the feasibility of deploying these technologies on industrial scales. A strategic roadmap is proposed that integrates scientific innovation, regulatory alignment, and carbon accounting in the life cycle to accelerate the adoption of carbon-storing concrete. This perspective provides a comprehensive framework to advance cement and concrete as engineered carbon sinks and supports the transition to a climate-positive construction industry.

Carbon storage↗
DOE OSTI2024

Reducing the cost of home energy upgrades in the US: An industry survey

Decarbonizing the US residential building stock requires a substantial acceleration in home energy upgrades. Numerous barriers exist to accelerating adoption of efficient and electric building technologies, but foremost among these is high upfront costs. This study uses an industry survey delivered to a sample of home energy professionals to examine promising cost reduction strategies across a range of project types, including HVAC, water heating, and envelope/insulation projects. The survey included quantitative and qualitative questions to collect evidence on the estimated cost reduction potential of these strategies and their likelihood of use in the construction industry. The 167 survey respondents included contractors, energy consultants, architects, manufacturers, and others with experience in delivering energy upgrades in single-family and multifamily buildings in the US. Results show that significant cost reductions are achievable by minimizing additional infrastructure costs (such as replacing electric panels), streamlining project planning/management, and deploying innovations that simplify installation. We find that for a typical deep retrofit project, including heat pumps for space and water heating in addition to envelope upgrades, the strategies could result in a total installed cost reduction of nearly 50%, dramatically improving the customer economics of such a project. This research makes a novel contribution to the literature on strategies to reduce the costs of residential retrofits. We discuss how our study's insights on the highest-value cost reduction strategies for home energy upgrades can further accelerate their uptake in the US housing stock.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Cost-Efficient Construction at Los Alamos National Laboratory

The construction industry can be fraught with cost, schedule, and scope overruns. Los Alamos National Laboratory (LANL), a Department of Energy (DOE) / National Nuclear Security Administration (NNSA) facility located in Northern New Mexico, seems to be particularly vulnerable to cost and schedule overruns. Since Triad National Security, LLC acquired the management and operating (M&O) contract for LANL in 2018, the group has been striving to reduce the cost of construction across the forty square-mile campus.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗