Construction

In building SAM there are three primary objectives with each material chosen:

1. Will it last 15-30 years?
2. Does it provide the required strength and seal?
3. Does it off-gas once cured?

The SAM team has gained a deep understanding of working with metal, from cutting to cleaning, welding to grinding, primer, and paint, and with foam insulation panels and plastics too. The fiberglass reinforced panels (FRP) were installed in the 20 foot shipping container (SAM Workshop) over preformed Insofast panels. Given that the walls of the shipping containers cannot be penetrated for the potential of forming a leak, nor can the 40′ be welded due to the potential of melting the insulation between the stainless (interior) and aluminum (exterior) walls, adhesives must be employed. With a selection of dozens of brands and types, each of which carries its own marketing and promises, the SAM team has learned (sometimes the hard way) what works and what does not.

Silcone-base adhesives will adhere to most materials, but the final product is not a structure bond, the kind that can carry a load. While the Dow Corning 795 is foundational to the success of Biosphere 2, the Test Module, and SAM, it is not applied where load-bearing elements come to play (e.g. the shipping container wall, aluminum-based foam panels, and furring strips).

Loktite PL3 is the low-VOC adhesive recommended by Insofast and used in their instructional videos. While the final, cured product is stable and strong, it was learned that this product loses integrity when pressed too thin between the adhere layers. When pressed to a few thousandths of an inch, as is desired with wood glue, the product fails and the two layers can be separated by hand. But with the toothed ribs of the Insofast panels, the PL3 bead remains 1/8-1/4″ and provides substantial integrity, as marketed. However, this presents a challenge if the surface of bonded layer must remain parallel to the underlayment or even across multiple panels.

Sika Construction Adhesive is not found in the adhesives section of the local vendor, rather with concrete block and building materials. It is much thicker than PL3, gray in color, and does not appear to harden completely, rather it remains relatively flexible yet holds to a greater diversity of surfaces, including FRP. It is very difficult to work with, but holds to polystyrene where PL3 specifically states it cannot adhere to this medium.

Roberts 7200 Base Bond is a very different kind of product from the PL3 or Sika adhesives. It is much easier to work with, spreads with a toothed trowel and covers like oat paste. It is “zero” VOC (1g per liter according to the package) and has no odor when being applied. It provides quite a bit of working time in low temperatures, and can be cleaned up with water before it begins to harden. However, it must have at least one porous surface in order to form a bond, with the other surface designed for vinyl baseboard trim. The instructions make it clear that even a coat of paint on the wall must be removed in order for the paste to adhere to the wall board.

Tightbond III is the standard among woodworkers, the strongest of this family of wood glue products, and a staple in any wood shop. As the amount of wood in SAM is limited, it was used only to build the reinforced door frame and overhead beam that gives tremendous strength and stability to the nearly free-standing SAM bathroom.

Nashua Aluminum HVAC tape is what Mark Watney should have brought to Mars. It is one of the most versatile, capable products on the market, and the modern replacement for duct tape. While 795 and rivets have been used to seal more than 200 holes in the refurbished 40′ container (SAM Crew Quarters), it is aluminum tape that has properly secured the entire interface between the stainless steel walls and aluminum roof. We found it to be highly adhesive, malleable (to a limited degree), water resistant, and air tight.

This following test matrix was developed by SAM team member Luna Powell. All samples were tested at 24 hours, 3 days, and 5 days. The following summary is at the close of 5 days.

Adhesive	Wood	Backer Board	Aluminum
PL3	Cured to the point of not moving	Strong, almost impossible to peel up	Did not even adhere (at all)
Sika	Remains soft to the touch after ~5 days curing	Remains malleable, not impossible to peel up	Peeled up easily
Base Bond	Won’t shift side to side, but easy to peel up	Readily peels up; did not stick to backer board	Peeled up easily; wet in the middle

With bonded interfaces between dissimilar metals, metal to foam, foam to wood, wood to wood, and wood to polystyrene, the types of applied adhesives varies. This past month has seen a good bit of experimentation, some failure, and success with what is hoped to be a multi-decade solution. While there are certainly many more to explore, from off-the-shelf two-part epoxies to marine grade epoxies; from UV activated cements to fire resistant silicones, SAM has been built principally from what is immediately available from the consumer market.

From January 16-27 the SAM construction team continued to check off tasks, one by one. With the bathroom platform (originally built in April 2022) reinstalled, and the hole drilled for the toilet outlet, the waste water storage tank was adjusted to its final position and secured, the inlet and vent openings cut and rubber flanges installed.

Construction of the bathroom walls was conducted from the shower stall to the door and then far wall, each section building upon the prior for both placement and stability. With very limited space (even if luxurious by NASA standards), every fraction of an inch had to be just right, literally built around the shower basin on three sides while leaving room for the plumbing that will be the 100% recycled water system with small water storage, pump, and filters.

Two significant challenges emerged: building a sturdy, essentially self-stabilized bathroom box within the 40′ shipping container without penetrating the walls, as a screw or rivet could introduce a leak point behind a structural member we’d never be able to reach again; and minimizing condensation formed at the interface of warm, moist air (from the shower) and the cool, interior metal lining of the 40′ shipping container in the winter months. We decided to enclose the top of the shower to reduce condensation and to give us an overhead surface on which we can mount a water storage tank, pump, and/or filter.

The steel bathroom door was reduced in height to match the vertical dimension of the crew quarters-to-workshop bridge. This required a rebuild of both the top and bottom, and total refabrication of the door jam itself. The end result is beautiful and strong, with interlaced, laminated joints. The bathroom has been a work in progress since the start of 2023, and will surely require a few more, but it will be well worth the effort when complete.

We chose colors from the SIMOC-SAM logo to hi-light a few exterior elements of the physical SAM structure, including the lower, outer lung wall and the outer entrance to the Test Module. Sean continued his critical work in revitalizing the three pressure doors, all original to the Biosphere 2 experiments of the 90s. This included multiple applications of PB Blaster, a steel brush, and bucket of soapy water.

In addition to the physical work at SAM, critical components and key appliances were ordered, including the electric actuated valve control the SAM AIR blower, convection microwave oven, bread maker, rice cooker, and water filters. A WiFi hotspot will provide internet for the first mission until a narrow-beam transceiver is in place, providing dedicated, point-to-point communication from Mission Control to SAM itself. The SAM internet and email server is ordered and on its way, with a very unique means to simulate the light travel-time delay developed just for SAM.

Yes, the title of this essay is an often used phrase, but one for which we seldom tire—especially when we have a tunnel, and with the final coat of paint the light really is brighter!. We are entering 2023 with a tremendous sense of accomplishment and forward momentum. For the hundreds of tasks we completed in 2022, many of which were monumental, multi-week undertakings, what remains is an exercise in a half dozen well defined projects (with many components) until all systems are functional.

Every Sunday evening SAM project lead Kai Staats delivers an email to the team with a list of items accomplished, those that remain, and where to focus our effort. The top five foci for December into the New Year are:

1. Sealing SAM, with validation through consecutive pressure tests.
2. Electricity in the 20 and 40 containers, then finish in the TM.
3. Complete the bathroom construction, then add power and running water.
4. Build-out the kitchen, shared space, and sleeping quarters.
5. Build-out the sensor array and start collecting data.

And a summary of most (not all) of the tasks completed in the past 45 days:

Test Module
– Install and seal 2 replacement windows – DONE
– Sand TM-to-lung tunnel – DONE
– Prime TM-to-lung tunnel – DONE
– 2x coats white enamel paint TM-to-lung tunnel – DONE

Workshop (20′ container)
– Complete roof panels – DONE
– Install all wall panels – DONE
– Poor concrete and mount workshop mini-split A/C condenser – DONE
– Install furring strips at bridge-end – DONE
– Fill voids with 1/2″ insulation panels, spray foam edges – DONE
– Install FRP at bridge-end – DONE
– Mount workshop electric power panel – DONE
– Mount electric power mounting rails – DONE

Crew Quarters (40′ container)
– Complete fabrication of the 40′ pressure door – DONE
– Clean, prime in/outside of 40′ pressure door interface – DONE
– Remove former name and logo from both sides of 40′ – DONE
– Prime bare metal areas of exterior – DONE
– 2x coats white enamel on exterior top/bottom trim, faces – DONE
– Seal floor edge at south end of 40′ – DONE
– Install insulation at door-end – DONE
– Install furring strips at door-end – DONE
– Fill voids with 3/4″ insulation panels, spray foam edges – DONE
– Install RFP at door-end – DONE
– Install FRP in the bathroom – DONE
– Mount RV wastewater holding tank – DONE
– Install toilet and drain – DONE
– Continue to pressure test, patch and seal …

We now move into the second half of January focused on electricity, plumbing, food prep, shower and toilet, and sleeping pods. Almost there!

As one who has managed teams for more than thirty years, in computer software development, business, and construction, I have come to recognize a number of things about myself in that leadership role: I work best with a dozen or fewer individuals; I am often the most difficult person on my team while setting an example for how to work through difficult times; I am thrilled when my team members arrive to solutions that surpass my own, when someone learns a new skill or accomplishes something for which we are proud.

It doesn’t really matter to me what we are doing together—landscaping, metal work, electrical wiring or plumbing, computer software, robotics, or combining them all to build a Mars habitat—as long as we are engaged in a manner that celebrates who we are as individuals and how we perform as a team. It’s about finding a rhythm, a dynamic, flexible flow even when the music is always changing.

In the fall of 2020 Trent and I estimated that SAM could be operational in six months with a half dozen volunteers, then grow over time. With the close of January 2023 we will complete our second year of construction with some thirty volunteers and contracted team members. SAM has grown, the physical habitat itself now part of the experiment. The end result will be a higher fidelity facility than we had originally envisioned, with substantial opportunity to grow.

SAM is a work of passion and a labor of love. It is the kind of project that people will look back to and say, “I was a part of SAM, I was there at the beginning.” We’re doing something wonderfully unique while echoing the work of the original Biospherians, our hands directly involved in metal, glass, and paint. I would not build SAM any other way for no amount of funding can replace the experience we have gained, and the sense of accomplishment each team member carries with them.

When visiting research teams engage SAM we hope they will carry findings, ideas, and personal experience to help shape a better world here, today, as we prepare to become interplanetary. —Kai Staats, Director of Research of SAM at Biosphere 2

We often speak of multitasking as a measure of performance or value in a fast paced society, yet the quality of work of any one individual is readily correlated to focus on a single, given task. In our work at SAM we do move through a half dozen projects in a single day. However, with an unwritten agreement to keep cell phone interruptions to a minimum, regular check-ins to revise the chalk board task list and tools in hand, we are a dynamic team, each of us able to transition from landscaping to metal fabrication, from concrete mixing to painting without hesitation. And in each task, that is our core focus from start to completion.

This past few weeks has seen our team struggle to get the 40 foot shipping container air tight, with far more leaks than anticipated. A few shipments and contracted component builds have seen delays too. We have taken advantage of the delays in one arena to make significant strides in others, tasks that might have otherwise been put off until March or April.

Sanding, priming, and painting much of the exterior of the two shipping containers and airlock, Test Module to workshop interior bridge, workshop to crew quarters bridge, and workshop floor are now complete. The upper lung pan and lower lung wall are primed. Luna has planted a “soup mix” in the experimental soil grow beds while John Z., Luna, and Bindhu were successful in pouring a concrete footing for the workshop mini-split condenser. Sean tackled the arduous paint scraping in the lung tunnel and Ezio came out from his programming lair to assist with landscaping and painting, his tenacity for detail welcomed. Kai, as usual, shuffled between all projects in order to keep the team focused and moving forward, providing sharp tools, ample supplies, and (mostly) appreciated guidance while trying to get back to the one thing he promised himself he’d get done that day.

As shared in a prior post, Kai Staats and Nathan Schmit were successful in cutting free one of the original pressure doors from the basement of Biosphere 2. This door had not been used for some twenty years and is a perfect fit for SAM, where it will serve as an emergency exit from the Crew Quarters space and provide a small but vital natural lighting portal.

It was the original intent to retain nearly the full steel plate into which the door was mounted such that it would fit neatly into the opening of the 40 foot shipping container without additional framing. However, upon inspection prior to cutting, Nathan and Kai discovered that that heavy 1/8″ thick sheet was heavily warped and would have been very difficult to weld without a great deal of bending and fill. Therefore a small frame was cut around the door. While the total mass was reduced to ~150kg (330lbs), some rigging and planning was required to safely maneuver the door into position in its new frame.

As with the end of the 20 foot container, the original doors were removed and 1″x3″ steel tubing was installed as frame and studs. The tubing is bolted to the thick steel frame of the shipping container, with temporary brackets holding the studs until welded. Nathan welded the studs to the frame, then the door, and finally the 12g sheet metal which forms an air-tight seem around the entire frame and to the door.

During the SIMOC-SAM Team Summit the first full SAM pressure test was conducted with the 40 foot container end in place. While the welds themselves held strong, leaks between the layers of the original floor were detected and then mitigated over the subsequent three days, before the holiday break.

The SAM Workshop will house a power panel, mini-split heating and cooling, 3D printer, sewing machine, and repair bench with a variety of tools for in-hab repair and fabrication. This room has a five layer sealed floor topped with steel sheets and Insofast brand, closed-cell foam panels with built-in plastic studs. On these panels we have added fiberglass reinforced panels (FRP) to protect the insulation, provide a strong structure on which to mount electrical conduit, shelving, and lights; and provide a readily cleanable surface.

The south end of the 40′ shipping container, soon to be completed as the crew quarters at SAM, will include an emergency exit for visiting crew. We are proud to have been gifted yet another pressure door assembly from the original Biosphere 2. Kai and SAM team member Nathan cut and with the help of Tim move the mass from the ‘technosphere’ to SAM. Nathan spent the better part of a day preparing the door frame for welding. On Tuesday, December 13 it will be attached to the new steel stud wall, and soon thereafter put into function for the first time in some twenty years.

Patching the 40 foot shipping container has proved to be significant challenge, setting us back two weeks from our intended schedule. Yet, each day we make progress toward a functional pressure vessel, each test demonstrating that our efforts are worth while—the audible space grows more quiet and the rise in pressure more rapid.

In parallel Luna and Kai applied paint to the workshop floor, bridges, and exterior roof of the airlock while Ezio (visiting from Italy) and Grant (visiting from Vietnam) worked on SIMOC Live, a new version of the Mars habitat simulator that will function as the live data capture system for SAM, collecting data in real-time from dozens of in-hab sensors.