Postcards from Mars

The final hydroponic racks are complete!

After Sean and Luna built out prototype #4 earlier in the summer and decided that was the system that suited SAM best, Luna and Matthias got to work building three more copies in August. They were joined by Linda Leigh who was added to the SAM team in order to further her knowledge on hydroponic systems and be more involved at SAM. With their combined strengths they got to work assembling the racks.

The first step was to build the skeleton of the rack. Using 80/20 they built up the sides, leveled the bottom and added the shelves. Once everything was level and secure they moved on to adding the plant trays, two per shelf. This involved meticulous and precise cutting of the trays, then cleaning up and gluing caps on the ends. Once they were satisfied with the end result of the trays, it was all about PVC. They built out the pump, intake manifold, return manifold and water drops for each shelf. This took the majority of the time, measuring, cutting, gluing, testing and putting together.

There were a lot of ideas how everything should get done and what the final product should look like. With a couple shipping delays the team was finally able to test the racks. To their amazement there were no significant issues with the system—no large leaks or anything that could not be fixed with a few turns of a union. With just 3 days left to spare, everything was ready for the tomato experiment to go in on September 2nd! —by Luna Powell, Site Manager and Greenspace Researcher at SAM

When the original rain forest greenhouse was built in the mid 1980s, it was known that the polycarbonate panels would need to be replaced, eventually, but by whom? With one round of repair (based on a discussion with a long-time Biosphere 2 staff member), they lasted more than 30 years. But in the end, the roof and all wall panels must be replaced. This effort began two years ago with replacement of the roof (see Through the Roof and New Roof) and continues now with the four walls, the East and West in the worst shape given the intensity of the sun, wind, and rain.

Matthias, Sean, and Luna have spent three months, juggling myriad other tasks, with this no-one-really-wants-to-do-it task. Matthias has lead the charge, holding the team to a high quality standard. There is nothing simple or easy about it, and no contractor could do a better job. Each panel must be custom cut to match width and height and curve of the overhead greenhouse arches. The top of each panel must be sealed with aluminum tape. Two kinds of screws are applied, some with sealed gasket roofing heads, other rubber backed washers to spread the pressure and keep out the water. The final product is then caulked with 795, a product that will likely outlast the new panels themselves.

The end result is stunning!

Kai, Matthias, and Luna have continued to work on the SAM Ops kitchen in between the third crewed mission and construction of the Mars crater, and when the sun was simply too damned hot to be working on installation of the polycarbonate panels at the Mars yard.

In early 2024 Kai installed the kitchen cabinets, essentially rebuilding the otherwise flimsy cabinets purchased from Home Depot (lesson learned, again) with nearly 40 feet of 2×4 framing added beneath and behind to provide something rigid and long lasting. The team deliberated on the kind of countertop, from prefab Formica to custom concrete to copper or glass. In the end, butcher block was chosen as it continues the Ops theme of hi-tech space exploration brought back down to Earth with wood desks, window blinds, and futon frames.

Installing under-counter support frames was the most challenging endeavor for the interior of this fully renovated 1990s manufactured building are steel studs—the worst for any kind of addition. Using various anchors and bolts, the butcher block counter was installed and prepared for the sink and backsplash tile.

Matthias conducted a good bit of research and sorted through the various techniques to determine the best combination of mastic, grout, and tile. His meticulous craftsmanship shines through in the gorgeous end product (grout yet to be applied).

With the refrigerator and microwave in place, a food prep island and dishes already received, we are nearly complete with the SAM Ops kitchen and eatery.

With the completion of the sculpted Mars yard and third Analog Astronaut Conference hosted by the Biosphere 2, the SAM crew moves into its second summer of continued effort, with a number projects unfolding at the same time. Last year Matthias Beach, Sean Gellenbeck, Tasha Coelho, and Mason Robbins worked June through September to complete renovation of the former Biosphere 2 rain forest greenhouse in preparation for installation of the SAM Mars yard, with an expanded and far more functional workshop for continued fabrication and construction.

Now, Matthias and Luna are completing the replacement of the original polycarbonate with new, darker tinted panels for less total thermal gain. The old panels had become brittle and were broken in many places, some sections blown out from strong, Arizona winds. With the new roof installed in July of 2022, all new wiring and rebuilt west wall in the summer of 2023, this begins the final effort to give this 1980s construct a new purpose for the next decade or two.

When it’s too hot to be on the scissor lift in the Arizona sun, Matthias is working in the SAM lower lung, replacing the original, rigid electrical conduit with Carflex, restoring the 3-way light function, and replacing the original florescent lights with modern LEDs for less power consumption and greater reliability. Luna is assisting Matthias and painting conducting the final scraping, sanding, priming, and painting of the lung walls and pan rim. This is the last, major interior restoration of the original Test Module and lung.

Kai, Matthias, and Luna continue to renovate the SAM Operations Center with the recent installation of a custom built butcher block countertop, sink, microwave, fridge, and more while Luna brings order to the chaos of the storage room following a juggernaut April and May.

Sean and Luna are designing and mid June fabricating the third prototype of the hydroponics rack. Once proved with a full growth cycle, three additional units will be built to complete this phase of bioregeneration capacity building with the ultimate goal of reproducing Linda Leigh’s single crew member, three weeks stay in SAM with all air fully recycled by plants.

We are honored to have Dr. James Knox, a former, career NASA aerospace engineer and principal developer of the CO2 scrubber for the International Space Station now working with us to design a custom scrubber for SAM. This original design and fabrication, lead by Sean, will enable us to engage full mechanical air recycling such that we can move from physico-chemical to bioregeneration in a single mission—the underlying goal for both the SIMOC simulator and the real world SAM research station.

Bindhu is updating the SAM Operations Manual, crew “cuff notes”, and working to establish an umbrella IRB. This is imperative for ability to engage multiple science objectives at SAM that carry data relevant to human related research objectives.

Tasha is working with Kai to develop the foundation for an educational curriculum around the new geologically accurate Mars yard such that primary and secondary school kids might enjoy an hour or a half day at SAM exploring the Mars yard through experiential learning and discovery. The same foundation will also apply to more advanced exploration by SAM crews, drones, and rovers.

Needless to say, we remain engaged!

As with the prior three summers, these photos essays will be reduced in frequency until September or October.

Stay cool! And stay tuned!