Melanie P. Bodiford’s research while affiliated with National Aeronautics and Space Administration and other places

A concrete specimen made with sulfur and a soil material similar to that found on the moon (stimulant) was tested in compression. The stimulant was developed and characterized under the auspices of the Johnson Space Center and is referred to as JSC-1. The addition of silica to sulfur concrete was found to increase the compressive strength by as much as 26%. This addition of silica to the sulfur concrete decreased the amount of sulfur required and improved the mechanical properties of the system. Results also showed that sulfur concrete exhibits no reduction in strength when subjected to severe freeze and thaw exposures or to prolonged freezing. The failure mechanism for the specimens is unchanged under these conditions, being similar to that at room temperature. In line with this work, the Marshall Space Flight Center (MSFC) and the UAH are currently modifying a previously developed subscale concrete extrusion system to make it possible to fabricate structures of greater complexity on a larger scale and to experiment with nozzle design and material as function of required abrasive resistance and temperature among others.

This paper reports the results of an ongoing research effort aimed at developing "waterless" concretes based on JSC-1 lunar regolith simulant. "Waterless" concrete, composed of lunar regolith used as an aggregate, and either a provisioned binder or a binder extracted from lunar regolith, such as sulfur, which is used as a cementitious material. The paper also presents several concepts utilizing this concrete for lunar habitat integrated construction. Integrated construction technology trade study data are presented, along with conceptual designs of these concrete application methods. Results of initial technology prototype development efforts are reported.

For long duration missions on other planetary bodies, the use of in situ materials will become increasingly critical. As man’s presence on these bodies expands, so must the structures to accommodate them including habitats, laboratories, berms, garages, solar storm shelters, greenhouses, etc. The use of in situ materials will significantly offset required launch upmass and volume issues. Under the auspices of the In Situ Fabrication & Repair (ISFR) Program at NASA/Marshall Space Flight Center (MSFC), the Habitat Structures project has been developing materials and construction technologies to support development of these in situ structures. This paper will report on the development of several of these technologies at MSFC’s Prototype Development Laboratory (PDL). These technologies include, but are not limited to, development of extruded concrete and inflatable concrete dome technologies based on waterless and water-based concretes, development of regolithbased blocks with potential radiation shielding binders including polyurethane and polyethylene, pressure regulation systems for inflatable structures, production of glass fibers and rebar derived from molten lunar regolith simulant, development of regolithbag structures, and others, including automation design issues. Results to date and planned efforts for FY06 will also be presented.

1. Habitat Structures at MSFC is one element of the In-Situ Fabrication and Repair (ISFR) Program: ISFR develops technologies for fabrication, repair and recycling of tools, parts, and habitats/structures using in-situ resources. ISRU - based habitat structures are considered Class III. 2. Habitat Structure Purpose: Develop Lunar and/or Martian habitat structures for manned missions that maximize the use of in-situ resources to address the following agency topics: bioastronautics critical path roadmap; strategic technical challenges defined in H&RT formulation plan: margins and redundancy; modularity, robotic network, space resource utilization; autonomy, affordable logistics pre-positioning.

As the nation prepares to return to the Moon and subsequently to Mars, it is apparent that the viability of long duration visits with appropriate radiation shielding/crew protection, hinges on the development of habitat structures, preferably in advance of a manned landing, and preferably utilizing in-situ resources. A relatively large number of habitat structure configurations can be developed from a relatively small set of in-situ resource-based construction products, including, blocks, raw regolith, reinforced concrete, and glass products. A much larger group of habitat designs can be developed when "imported" material are brought from Earth, including thin films and liners, and foldable, or expandable metal structures. These, and other technologies have been identified, and subjected to a rigorous trade study evaluation with respect to exploration and other performance criteria. In this paper, results of this trade study will be presented, as well as various habitat structure design concepts and concepts for construction automation. Results of initial tests aimed at concrete, block and glass production using Lunar regolith simulants will also be presented. Key issues and concerns will be discussed, as well as design concepts for a Lunar environment testbed to be developed at MSFC's Microgravity Development Laboratory. (MDL).

For long duration missions on other planetary bodies, the use of in situ materials will become increasingly critical. As man's presence on these bodies expands, so must the structures to accommodate them including habitats, laboratories, berms, garages, solar storm shelters, greenhouses, etc. The use of in situ materials will significantly offset required launch upmass and volume issues. Under the auspices of the In Situ Fabrication & Repair (ISFR) Program at NASA/Marshall Space Flight Center (MSFC), the Habitat Structures project has been developing materials and construction technologies to support development of these in situ structures. This paper will report on the development of several of these technologies at MSFC's Prototype Development Laboratory (PDL). These teckologies include, but are not limited to, development of extruded concrete and inflatable concrete dome technologies based on waterless and water-based concretes, development of regolith-based blocks with potential radiation shielding binders including polyurethane and polyethylene, pressure regulation systems for inflatable structures, production of glass fibers and rebar derived from molten lunar regolith simulant, development of regolithbag structures, and others, including automation design issues. Results to date and planned efforts for FY06 will also be presented.