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Industrialized and Robotic Construction Advances in Terrestrial Construction and Opportunities in Space Construction

Advanced Building Construction (ABC) methods such as industrialized prefabrication and robotically controlled additive deposition are becoming promising technologies to support rapid construction of buildings at volume and scale. However, apart from the structural shell of the building, optimal integration of other systems – mechanical, electrical, plumbing, thermal, power generation, storage and distribution, is key to enabling functional buildings. Leveraging ABC methods to integrate such systems in the buildings requires the building design to be optimized for constructability constraints imposed by the industrialized and robotically controlled production setups entailing such ABC methods. The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been focusing on research and development of such ABC technologies and processes that can lead to production of buildings which are resilient to extreme climatic conditions at reduced cost and time. There is a potential synergy between such advancements in terrestrial construction, which can be leveraged for the benefit of space (orbital and extra-terrestrial) construction. Similarly, advances in space construction can lend itself to accelerated adoption of robotic construction methods in terrestrial construction. This presentation will give an overview of selective research efforts of the ICI team at NREL, along with a vision for potential collaborations with agencies like NASA.

3D printing↗

ADVANCED CONSTRUCTION TECHNOLOGY INITIATIVE (ACTI)

Advanced reactor technologies have attracted considerable financial support, catalyzing innovation in the nuclear energy landscape. These next generation reactors are designed with enhanced passive safety systems and the potential for cost reductions. As these advanced reactors approach technological maturity, their commercial success also requires focused examination and essential support. Economic assessments in the nuclear energy sector often emphasize construction costs and the risk of scheduling delays as primary contributors to deployment expenditures. Traditionally, vital elements of nuclear energy deployment including civil/structural engineering, design sophistication and automation have been either undervalued or postponed in the development cycles. Additionally, the nuclear industry’s collective experience in nuclear project execution has diminished over the past several decades due to the infrequency of new plant constructions. Hence, The National Reactor Innovation Center’s (NRIC) Advanced Construction Technology Initiative (ACTI) program aims to reduce cost overruns and schedule slippages that have plagued the construction of nuclear power plant projects. With this initiative, NRIC is facilitating the development of advanced nuclear plant construction technologies and approaches through partnerships that would provide game-changing benefits to the construction of advanced nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Perspectives on Potential Advanced Construction Technologies for Nuclear Energy

Advanced reactor technologies have attracted considerable financial support, catalyzing innovation in the nuclear energy landscape. These next generation reactors are designed with enhanced passive safety systems and the potential for cost reductions. As these advanced reactors approach technological maturity, their commercial success also requires focused examination and essential support. Economic assessments in the nuclear energy sector often emphasize construction costs and the risk of scheduling delays as primary contributors to deployment expenditures. Traditionally, vital elements of nuclear energy deployment including civil/structural engineering, design sophistication and automation have been either undervalued or postponed in the development cycles. Additionally, the nuclear industry’s collective experience in nuclear project execution has diminished over the past several decades due to the infrequency of new plant constructions. Hence, the National Reactor Innovation Center’s (NRIC) Advanced Construction Technology Initiative (ACTI) aims to reduce cost overruns and schedule slippages that have plagued the construction of nuclear power plant projects. With this initiative, NRIC is facilitating the development of advanced nuclear plant construction technologies and approaches through partnerships that would provide game-changing benefits to the construction of advanced nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Advanced Construction Technology Initiative Program: ACTI Phase 1 ACTI Phase 2

Demonstrate technologies to significantly reduce the cost and schedule for construction of advanced reactors. Demonstrate the technology by 2026/2027 to improve the economics of deploying advanced reactors. Selected technologies will not require major R&D efforts. With prototyping and testing, the technologies will be ready for deployment at scale.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Phase I Summary of Management Activities - Advanced Construction Technology Initiative Project

As the end of the year is approached, it is essential to review the National Reactor Innovation Center (NRIC) management activities undertaken during the Advanced Construction Technology Initiative (ACTI) project. The ACTI project was launched to support a transformation in nuclear energy construction, management, and deployment costs, enabling nuclear energy to make important contributions to the energy systems of the future. This transformation will increase the confidence of investors, energy system planners, policymakers, and ultimately consumers in the capability of nuclear energy to meet future needs; thus, it represents a critical element of advanced nuclear energy system demonstration. Development and/or demonstration project(s) will consider regulatory requirements for commercial nuclear implementation and will incorporate strategies to develop regulator experience and review of the technology. GE Hitachi (GEH), a leading player in the nuclear industry that offers a range of products and services including nuclear reactor design, fuel supply, and decommissioning solutions, submitted a proposal for the ACTI project. GEH was awarded the contract for the first phase of the project.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Perspectives on Potential Advanced Construction Technologies for Nuclear Energy

NRIC Enables Nuclear Reactor Tests & Demonstrations Authorized by the Nuclear Energy Innovation Capabilities Act (NEICA) DOE-Office of Nuclear Energy; INL Nuclear Science & Tech Partner with industry to bridge the gap between research and commercial deployment Leverage national lab expertise and infrastructure

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Advancing Construction through the Buildings Workforce: Preprint

Buildings are America's energy hogs, consuming over 70 percent of all electricity and over 50 percent of all natural gas produced across the country. Achieving a clean energy future requires us to reinvent how buildings manage energy resources and how consumers demand it. The U.S. Department of Energy is investing in a range of technological advancements that are paving the way to a future where buildings are no longer simply energy consumers, but rather are part of an integrated system that help manage energy resources in a way that supports the electricity grid. This paradigm shift presents an opportunity to increase the efficiency of the built environment, but will only be realized if we build a knowledgeable workforce to design, construct, and operate these high-performance buildings in step with the rate of technological advancement.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗

Modeled Results of Four Residential Energy Efficiency Measure Packages for Deriving Advanced Building Construction Research Targets

The Advanced Building Construction (ABC) Initiative from the U.S. Department of Energy Building Technologies Office is working to accelerate industrialized construction innovations for decarbonizing buildings. To inform performance and cost targets for research under the ABC Initiative, this analysis used the ResStock™ tool to evaluate the energy savings, utility bill impacts, and carbon emissions impacts of four simulated upgrade packages with specific target performance levels on a large sample of residential dwelling units (approximately 550,000) representative of the U.S. housing stock.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Advanced Building Construction Collaborative (Final Technical Report)

This report summarizes the outcomes of RMI’s five-year U.S. Department of Energy–funded Advanced Building Construction Collaborative (ABC-C), which accelerated adoption of high-performance construction through industry collaboration, market research, technology commercialization, and demand aggregation. It highlights the Collaborative’s achievements—including engagement of more than 130 organizations, support for over $637 million in funding for ABC companies, and recommendations to scale advanced building construction through coordinated market, policy, and investment strategies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Advanced Building Construction (ABC) Research Opportunities Report: Industrializing Construction to Decarbonize Buildings

The DOE Building Technologies Office generally seeks to develop, demonstrate, and accelerate the adoption of cost-effective technologies, techniques, and tools in support of an equitable transition to a decarbonized building stock and energy system by 2050. This ABC Innovations Roadmap specifically focuses on and prioritizes innovations that support the industrialization of whole building retrofits and rapid growth of efficient new construction. The content relates to the integration of technologies and industrialization of processes associated with building construction and renovation. The ABC Innovations Roadmap cross-applies innovations in both the new and existing building sectors with a focus on widescale applicability. Installation flexibility is key to commoditizing solutions that are applicable for a wide variety of buildings (e.g., different building types, vintages, architectural details, and system configurations) and to help simplify decarbonization processes for the workforce.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Completing the Circuit: Workforce Development for Advanced Building Construction and Grid-Interactive Efficient Buildings

This paper will present key findings from a future-oriented qualitative study investigating likely futures for the next 5-10 years in the architecture, engineering, construction, and operations industry. This research offers an original contribution to the buildings industry by articulating an actionable framework to more effectively build connections between built environment fields. Whereas the ideal of interdisciplinary, research driven practice underlies the approach to pedagogy at many schools of architecture, innovation in the profession, such as the integrated design process, has been limited. This project applies Legitimation Code Theory (LCT) to the analysis of data gathered from interviews and a review of industry reports.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Advanced Building Construction (ABC) Research Opportunities Report: Industrializing Construction to Decarbonize Buildings

The U.S. building stock is responsible for 75% of total U.S. electricity use, 40% of energy use, and 35% of CO 2 emissions. To meet bold national climate change goals, the U.S. must decarbonize the building stock by 2050. However, today’s practices to build or renovate buildings to low-carbon, high-performance levels are generally labor intensive, disruptive, and too costly to quickly scale in the U.S. To retrofit 80% of the U.S. building stock in the U.S. by 2050, the retrofit rate will need to increase by about 15 times for residential buildings and two times for commercial buildings. Additionally, there is a major housing deficit in this country where nearly 600,000 people lack adequate or stable shelter, and the pace of construction is not keeping up with the growing demand. New, more industrialized, replicable, and technologically driven approaches to renovation and new building construction are imperative to help meet such significant national needs and achieve the necessary speed and scale to meet national building decarbonization goals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Machine Learning for Advanced Building Construction: Preprint

High-efficiency retrofits can play a key role in reducing carbon emissions associated with buildings if processes can be scaled-up to reduce cost, time, and disruption. Here we demonstrate an artificial intelligence/computer vision (AI/CV)- enabled framework for converting exterior build scans and dimensional data directly into manufacturing and installation specifications for overclad panels. In our workflow point clouds associated with LiDAR-scanned buildings are segmented into a facade feature space, vectorized features are extracted using an iterative random-sampling consensus algorithm, and from this representation an optimal panel design plan satisfying manufacturing constraints is generated. This system and the corresponding construction process is demonstrated on a test facade structure constructed at the National Renewable Energy Laboratory (NREL). We also include a brief summary of a techno-economic study designed to estimate the potential energy and cost impact of this new system.

building retrofits↗

Machine Learning for Advanced Building Construction

High-efficiency retrofits can play a key role in reducing carbon emissions associated with buildings if processes can be scaled-up to reduce cost, time, and disruption. Here we demonstrate an artificial intelligence/computer vision (AI/CV)-enabled framework for converting exterior build scans and dimensional data directly into manufacturing and installation specifications for overclad panels. In our workflow point clouds associated with LiDAR-scanned buildings are segmented into a facade feature space, vectorized features are extracted using an iterative random-sampling consensus algorithm, and from this representation an optimal panel design plan satisfying manufacturing constraints is generated. This system and the corresponding construction process is demonstrated on a test facade structure constructed at the National Renewable Energy Laboratory (NREL). We also include a brief summary of a techno-economic study designed to estimate the potential energy and cost impact of this new system.

build scans↗

Toolpath considerations for DED: Arc and laser welding

Directed energy deposition (DED) is a form of additive manufacturing that uses localized melted metal, similar to traditional arc welding, to construct an object. In comparison to polymer systems, metal systems can exert additional control over the build process through manipulation of the pool of melted metal, called the “melt pool.” This is especially important to maintain appropriate layer heights and create high quality builds. Additionally, metal systems allow site-specific control of the printed part, which enables advanced construction techniques that would otherwise not be possible. However, both of these types of control require support from the slicing software and, potentially, sensor feedback. This chapter will discuss these control processes and their basic implementation in a slicing program. The processes described here lay the foundation for more advanced solutions, particularly sensor feedback, that will be discussed later.

Borish, Michael↗

Entropy-defect synergy for dual luminescence mechanism in spinel: Time-resolved anti-counterfeiting and fingerprint visualization

Multimodal luminescent materials, while promising for anti-counterfeiting, often lack dynamic time-dependent responses and controllable spatial distribution, limiting their encryption capabilities in the spatiotemporal dimension. Here, this work presents a coordinated control strategy based on entropy and defect engineering, and uses a backpropagation (BP) neural network for material screening to successfully prepare spinel Mg 0.8 (Fe 0.04 Co 0.04 Ni 0.04 Cu 0.04 Zn 0.04 )Cr 2 O 4 (MgA 5 CO) phosphors with time-dependent dynamic luminescence behavior. This phosphor simultaneously activated the d-d transition luminescence (∼618 nm) derived from Co 2+ /Cr 3+ and the defect luminescence (∼398 nm) related to zinc vacancies (V Zn ) in a single-phase solid solution. The phosphor exhibits a time-dependent color evolution from pink to purple under fixed-wavelength excitation, due to the different excited-state dynamics and decay lifetimes associated with the d-d transition and defect luminescence. Structural characterization and spectral analysis confirmed the existence of V Zn and its significant role in defect luminescence process. The fluorescent and dynamic luminescent properties of entropy-based spinel oxide enable its use in advanced anti-counterfeiting applications like fingerprint recognition and color-changing dedicated anti-counterfeiting mark, showing promise in high-end and time-dynamic anti-counterfeiting fields. This research not only developed a new type of fluorescent dynamic anti-counterfeiting material, but also provided a new idea for constructing advanced optical functional materials with multiple luminescence mechanisms.

Defect project↗