Construction

The SAM team enjoyed an incredible work week, an all-hands-on-deck, sunrise to sunset (and beyond) engagement with Matthias, Luna, Sean, Bindhu, and Kai engaged in a non-stop effort to complete the SAM Operations Center and Mission Control, as well as advance the Mars yard into its next stage of development.

*Bathroom*
– shower tiles are grouted and cleaned
– sink is installed
– vanity light is installed
– toilet is set
– sliding doors and new head are hung

*Kitchen*
– countertop brackets are installed
– countertop template (plywood) is set
– butcher block is in-house; needs to be cut
– induction cook top arrived; waiting to be installed
– sink and faucet arrived; waiting to be installed

*Conference Room*
– 65″ TV installed
– 5.1 home theater speakers installed, cables run
– chairs and conference table cleaned
– “The Martian” watched !!!

*Mission Control*
– 4 mission control desks are installed
– LCD projector installed
– silver screen installed
– sound bar installed (and it sounds amazing!)
– all sheetrock work completed, painted
– IT rack assembled (needs to be reduced in size)

*Misc*
– all electrical breakers replaced
– fibre optic drop, ethernet, and WiFi are working with asynchronous 200 Mbps
– floors are washed (a few times)

*SAM*
– reduced gravity simulator removed and painted
– TM and 40′ hatches inspected, temp patched
– TM outlined on the Mars yard workshop floor
– hydroponics rough layout established; plans made
– Mars yard boulders moved (not an easy task)

This week we will:
– re-install the RGS at its working height
– build the gravity-offload rig (and test)
– remove the prototype Mars yard and basalt (ugh!)
– prepare for delivery of a 20′ section of our sculpted Mars yard on Thursday

We kicked butt and got a LOT done! And this next week we again have our work cut out for us!

For as laborious as it may appear, our team has enjoyed nearly every minute of this completely normal office remodel. We don’t have to worry about maintaining a hermetic seal, or the structural integrity of a hull under pressure, or the circulation of air and CO2 monitoring—rather, were engaged in the rapid (by comparison) efforts to reinforce and level a new kitchen cabinet, hang two new doors, scrub bathroom tile, install a toilet, paint, and rewire a few outlets.

Today, Thursday, January 11 marks the fourth day that our team has returned to SAM since a few days before the Christmas holiday. We all needed the break after another three months of intense activity. Mason and Natasha have returned to Europe, with Bindhu and Sean in their home towns of Dallas and Chicago respectively, conducting research and working on SAM related projects from afar.

Matthias, Luna, and Kai engage daily with Atila balancing his graduate degree, thesis research, and time at SAM. We will all come together again in just twelve days for a week of intense, hands-on work at SAM. For the remainder of January our goals will be the continued renovation of the building we now claim as the SAM Operations Center, a return to the reduced gravity simulator, and the installation of the new array of hydroponics racks, shelving, nutrient tanks, runs, and computer control systems.

What’s more, we are preparing for the construction of a 3000 sq-ft Mars yard, co-designed and expertly crafted by a leading Hollywood set design company. Stay tuned for the official announcement and design details!

The SAM Operations Center is nearly fully transformed from a former storage facility for B2 house keeping to an elegant, modern facility with conference room, workshop, storage, library-den, full bath, kitchen, and a full-featured Mission Control Center complete with desks for four officers and heads-up displays for SAM monitoring and communications.

Our first team lead by Christopher Cokinos will be in SAM the second week of March. Our own SAM team members will be establishing baselines for CO2 production in preparation for a full suite of bioregenerative experiments October-December 2024.

2024 is the year we fully transition from construction to scientific studies, data collection, and building our legacy in human space exploration.

Stay tuned!

Each of the five interior doors at the SAM Operations Center now celebrates one decade in human space exploration, with Mercury-Gemini, Apollo, Space Shuttle, and ISS in bold, large format prints. We are proud to make five generations of technological advancement and scientific endeavor central to our new Operations Center and Mission Control.

This was our holiday gift to ourselves, something out of the ordinary, something that will for many years to come give visitors reason to smile when they enter our facilities. We thank Ann Persnel and the team at West Press of Tucson for their expert printing and installation.

The reduced gravity simulator (RGS) at SAM is installed and operational with a single-axis test trolley. This marks completion of one of the most unique and advantageous components of SAM when coupled with pressure suit and rover mobility research. In it’s current state the RGS allows the SAM team to safely test various configurations of trolley and gravity-offload rigs before elevating to the nominal operating height. Once the gravity-offset rig is integrated, the entire 50 (15m) foot assembly of welded, tubular steel armatures and raceway will be raised to 12 feet (4m), providing a variable reduction in apparent weight from Mars (1/3) to Lunar gravity (1/6) to microgravity.

Once again we thank James Parker and the master welders at the University of Arizona welding shop for a perfect fabrication of the five RGS armatures.

Learn more about the history of reduced gravity simulators and the RGS at SAM and watch a video of the test of the static trolley.

The SAM Operations Center is well underway with three weeks completed. The storage room is painted, floor down, and shelves built. The workshop walls and floor are complete, with workbenches to be installed soon.

Last week Matthias and Luna built a quick prototype of a Mars yard wall section, the intent to visualize the avrage height and angle of a small section of what will be sculpted concrete over expanded steel. With the close of this week Matthias installed the final sheet of steel paneling on the sliding door then trimmed west wall roof sheets (installed in July 2022) while Luna painted, and Kai installed the new power distribution panel.

It’s been a long, hot summer followed by a far too warm September and October with a series of projects in the SAM Mars yard renovation that took far more resources than anticipated. With Matthias Beach in the lead, Sean Gellenbeck, Tasha Coelho, Mason Robbins and Natasha Nichols worked sequentially for the removal of all no-longer-needed electrical conduit, chasing new electrical wiring through the conduit that was retained, installation of a new electrical power distribution panel, mounting all new, outdoor rated electrical sockets, replacing the mostly defunct lighting (as one would expect after thirty five years), and a complete reconstruction of the west wall in order to install new steel siding.

The end result is incredibly rewarding as the Mars yard superstructure is very well lit, with isolated circuits on every wall, and a clean power distribution panel on a brand new backboard. With the new roll-up doors and steel roof overhead, the building is now completely secured from the weather, and from the critters too.

If one on my team members asks for the whereabouts of a tool more than once, then we have a breakdown in our organizational system and are wasting time. Stop and fix the system!”

Small, well organized teams can run circles around a larger, comparable entities, especially when their overhead is low and assets are well managed. Small teams respond to changing environments with less drag, and set course corrections by direction of a single leader or a raise of hands. But the means by which any size team organizes its “stuff”, analog and digital, determines if it holds accumulating assets or a growing burden.

SAM started with Kai Staats, Trent Tresch, a broom, two angle grinders and a face shield, two orbital sanders and a box of sand paper. Fast forward nearly three years and SAM is defined by a half acre of land, some 9,000 square feet in building space, and ample tools and supplies to fabricate just about anything in wood, plastic, or metal.

While we have maintained a regimen of organization, returning tools to their respective bins each evening and conducting a total inventory with the close of each week, we made due with the funds raised in each phase of development. We used plastic bins for tool storage and unused sheets of steel covered with cardboard as our workbench, just inside the north bay door of the Mars yard structure.

With advanced funding secured in July we saw an opportunity to improve our organization and related efficiency. We acquired a Husky mobile tool cart and a few more power tools to replace those yet on loan from our staff members. We gave new life to a discarded Biosphere 2 metal shop workbench topped with two sheets of recycled plywood. For us, this was a dream-come-true—our very own workbench and a dedicated tool cart.

The half day spent in building the workbench paid for itself in the first week. With the complete re-organization of every tool, bolt, nut, and washer; every strand of wire, every plumbing fitting, and every tube of silicone (Thank you Luna!) have dedicated, labeled bins and drawers.

“The bobcats at Biosphere 2 are anything-but-timid, curious, and clever. They watch us work by day and explore the Mars yard by night. When the work is overwhelming or the two-week task drags into its second month, its the wildlife that keeps us entertained and lighthearted.” — Kai Staats, Director of Research for SAM at Biosphere 2

The west wall of the original Biosphere 2 botanical garden Rain Forest Greenhouse, now our Mars yard and workshop, holds the power distribution for the entire facility. We’ve been working up to this point for a year and a half, with the removal of the old roof, installation of the new roof, and work this summer in July, and August and September.

This week saw the completion of the monumental west wall reconstruction, more than six weeks in the making. It required a systematic reassembly of the overhead load-bearing structure in order to insert the new corrugated steel wall panels into the overhead C-channel and against the steel base. After thirty years, some sections were so badly worn that we had to contract a local sheet metal shop to duplicate the exact profile and provide new pieces. All new plywood sheeting was installed to provide the backdrop for the new electrical panel and power distribution. With all new wire already in place, we will now complete the electrical wiring at each new socket and lighting.

From botanical garden to storage building to workshop and Mars yard, this former greenhouse has seen a variety of functions. And as with the TM and lung, the SAM team is once again breathing new life into old structures.

As with any pressure vessel, SAM has leaks. The current leak rate is higher than desired, therefore we are working to locate the holes, apply patches, and bring the total leak rate to a minimum. Our intent is to hold pressure for one week such that 6-day missions can pressurize the facility once, and with future, longer missions air will be added in a quantitative manner once each week, at most.

Recall that SAM has three modes of operation, where the first two missions were running in Mode 2, pressurized with flow-through air with a high degree of air quality monitoring, as noted in the data analysis. Inclusion II conducted two Mode 3 experiments in the course of their mission.

In the first part of June, Sean Gellenbeck and Matthias Beach isolated the lung from the rest of SAM, and then the lung and Test Module from the rest of SAM. In each instance they conducted a pressure test by raising the lung to roughly 36″, then closing the inlet valve and terminating the blower. The height of one of the eight lung feet was measured from the floor, and then again once each five minutes for one hour. The drop in height over time provides the total leak rate through the loss of the known column of air below the fixed diameter lung pan and membrane.

Leak rate = Pi * r^2 * drop (inches) * time (minutes)

While we do calculate the leak rate by volume of air, for ease of visualization we present it here instead as the loss in height of the lung.

With a max height just under 10 feet and a minimum height at zero, when one of the eight legs and feet touch the ground, the rate of descent is constant as the mass of the lung exerts the same pressure on the underlying column of air independent of its height. The temperature was measured with each height reading in order to provide raw height measurements and the height adjusted for temperature changes according to the ideal gas law.

The lung was found to have no significant leak rate, in fact, the lung rose during the one hour test due to a minor temperature increase. The lung and Test Module combined demonstrated a 1.3 inch lung drop per minute, or roughly 3.5 days sustained pressure if starting from the max height of 10 feet. The leaks in the Test Module will likely be readily corrected with a full application of silicone where two replacement windows were installed last spring.

In the first and second week of October, Kai, Luna, and Natasha moved into the next important test—isolating the Engineering Bay (20 foot shipping container) from the Crew Quarters (40 foot shipping container) such that the lung, Test Module, and EB are treated as a single vessel.

This proved to be a bit of a challenge as three electrical conduits, one fire detection conduit, and one water pipe run from the Engineering Bay into the Crew Quarters, making it very difficult to seal. It was determined that pulling all conduits was the simplest way forward. This included disconnection of the fire detection system, which required the UA Fire Marshall. Once the interface to the 20/40 bridge was clear of conduits, we sealed the far side with a plastic tarp and aluminum tape.

The lung, Test Module, and Engineering Bay combined demonstrated a leak rate of 0.1 inch lung drop per minute, or 19 hours sustained pressure if starting from the max height of 10 feet.

We have some work to do!