Construction

Two years ago this summer the SAM development team met via Zoom to discuss the best way forward for the Space Analog for the Moon & Mars. At that time, it had been our intent to move the Test Module, piece by piece, from its original location to the north yard of the Biosphere 2. This difficult task was, at that time, intended to give maximum exposure to SAM as it would be directly on the tourist walking path and in the shadow of Biosphere 2 proper.

However, through conversations with individuals at NASA we were reminded that for long-term missions isolation from tourists would be ideal, off the main campus with minimal disturbance. Furthermore, we could drastically reduce the cost of construction by leaving the Test Module on its original, sealed foundation. Once we changed that mindset, it opened a whole new way of embracing the project. And as is often the case, we saw what was right in front of us as something wholly beneficial with incredible potential.

When Biosphere 2 was opened in 1991, the visitor center and parking was above the Test Module. Tourists walked past the Test Module and a half acre botanical garden complete with working simulations of the biomes inside of B2. In this manner, tourists could experience some of the interior environment and learn about the analog experience without being sealed inside.

Last summer we removed five greenhouse structures to make way for our exterior Mars yard, a space that will be reconfigured for long-duration teams and for rover competitions. We retained the 6,400 square foot rain forest greenhouse with intent to replace the former plastic panel roof with corrugated, galvanized steel. In March we removed the remaining plastic panels (most had fallen to ruin after thirty plus years) along with a massive amount of aluminum framing, steel cables, and no-longer-in-use electrical components. Just two weeks ago we rented a scissor lift to complete this effort, the articulating ridge lines of each half dome removed.

When complete, the full steel roof far overhead, we will greatly reduce the thermal load on the Mars yard terrain, offer shade for crew members in already difficult to cool pressure suits, and reduce the ambient lighting to something closer to Mars than the direct, Arizona sun.

It took six months of research and negotiation to find a local company willing to work with this unusual building and within our limited budget. We are pleased to have engaged Skyland Roofing of Tucson, Arizona. The crew worked through difficult conditions, from 104F+ degrees to wind and rain, on scissor lift and cherry picker 24-40 feet off the deck. Thank you Skyland, foreman Mario, and crew Louis #1, Louis #2, Kevin, Elia, and Adrian for your services. And thank you LP Steel of Laveen, Arizona for the custom-made roofing panels delivered on time and at a reasonable price.

Following the Analog Astronaut Conference, the entire team took a well deserve break, a week without hammer, drill, construction adhesive, or paint in hand. Kai Staats was then in Washington D.C. to present to and participate in the National Space Society’s International Space Development Conference while John Z. and Luna constructed a prototype sleeping pod.

In preparation for the installation of a new corrugated steel roof over the indoor Mars yard at SAM, Luna and Kai spent two days on a scissor lift (photo at top) removing the remaining aluminum framework that held the articulating roof panels across the two ridges. Next week the contractor arrives to install the new roof. With just three weeks remaining in construction at SAM until October, it is our intent to install insulation in the workshop (20 foot shipping container) and a mini-split air conditioning unit in the crew quarters (40 foot shipping container), and continue our work toward the hermetic seal of the expanded habitat.

Stay tuned for more!

By Luna Powell

Given feedback from Kai, Sean Gellenbeck, and Anastasiya Stepanova whom have collectively attended four habitat analogs (MDRS, HI-SEAS, SIRIUS, Devon Island), we determined that the team members staying in SAM will benefit from their own private space to sleep, decompress, and work. This may seem obvious, but there are analogs (and real-life environments) in which private space is not afforded such as lava tube and submarine analogs, and the International Space Station.

We narrowed our brainstorming and initial designs to an enclosed sleeping module. While Kai was attending conferences around the U.S. mid May to early June, John Z and I turned our attention to creating an enclosed, private sleeping quarters prototype for future SAM crew members. We drew it out, purchased the materials, and built the prototype.

The idea was simple: an enclosed, insulated, sturdy, module with personal storage, bed, ventilation, and plenty of privacy. There will be 4 placed at the end of the 40ft shipping container, stacked and arranged with a sufficient amount of storage space as well as a place to sit on top, to create a vertical component to the shared common space for reading, resting, or working with a laptop.

Using ecoboard, backerboard, 2x4s, insulation foam, a substantial application of construction adhesive, and a bit of trial and error, the prototype took shape. The box itself sits around 87″ long, 33″ wide, and 47″ tall granting the person inside plenty of room to lie down, sit up, move front to back and sleep comfortably.

The team still has a plethora of ideas about how to set up a fan system, close off the opening, insert shelving, and much more. But with the close of construction for the summer, these ideas will have to be addressed in October when everyone returns.

In the final days before the Analog Astronaut Conference 2022, hosted at Biosphere 2, the SAM construction and fabrication team worked tirelessly, from sunrise to sunset to get as much of SAM ready as possible for the more than 100 attendees. While most of the effort was on the task list for Phase II, some undertakings were temporary, a light treatment of a room or space to provide visitors a glimpse of what will come.

After several weeks research, locating vendors, confirming inventory, tracking and motivating shipment, Dick and Linda Staats (Kai’s parents) delivered 320 sq-ft of all natural, VOC-free cork flooring to SAM at Biosphere 2 … and just in time to install with the close of Phase II construction before the Analog Astronaut Conference 2022.

John Z., Kai, Luna, Anastasiya, and John Adams worked to install the backer board and cork tiles over the course of four days, assuring each step was conducted with integrity. Each product selected, from the glue between the backer board and original aluminum rails of the 40′ shipping container, the backer board itself, and the cork (which was simply set down, not glued) were selected for their low- or no-VOC characteristics. Visiting teams to SAM will breathe easy in an environment far healthier than the average American home, and not far from what very well could be a Martian habitat.

What’s more, the flooring is simply beautiful, warm, and welcoming.

After more than 30 years the Test Module is once again living!

Thank you Dr. Giacomelli for your patient guidance to the assembly and operation of our new research system, and to Bill Nichols for your careful management of the transplant and fertilizer adjustments. Already, we can see the lettuce growing!

As in the spring of 2021, we are in another race to the finish with just 10 days until the Analog Astronaut Conference hosted by Biosphere 2. We have completed all major Phase II construction and are now moving to the interior space, installing flooring, shelving, kitchen and bathroom appliances, lights and a small SIMOC-enabled sensor array.

The effort is intense, 15-18 hours a day, with John Z., Luna, Bill, and Kai while Greg and Grant complete the effort to integrate a sensor array into the new SIMOC ‘Live’ interface. It’s an exciting, exhausting time!

The short list of TODOs includes:
– complete the exterior priming of SAM AIR and the adjacent wall
– lay the sub-floor and cork flooring in the 40′ container
– build 2 racks with shelving in the 20′ container
– move the CO2 scrubber into the 20′ container and build a workbench on the second rack
– complete the hydroponics and get the lettuce transported
– build a soil bed and transplant the Cascabel tomatoes
– complete the TM east wall electrical wiring
– install (without plumbing, for now) the toilet, shower, and sink
– install the skylight-window in the 40′ container
– sand and prime the airlock floor
– roll-out carpet in the walk zones
– continue landscaping under Luna’s leadership
– install the stainless steel kitchen appliances

Thank you James for providing us with the expert work of Charlie and Steven from the University of Arizona Facilities Metal Shop. They performed a minor miracle with their work today, both ends of the 20′ shipping container / SAM workshop now one step closer to being pressure ready.

We are becoming regulars are Superior Steel, Tucson, where every shape and size of factory steel can be found. It is a commodity that we take for granted, as we use steel products each and every day. Yet the tremendous volume of steel manufactured, distributed, purchased, and fabricated is astounding. Learning to work with steel is both a science and an art. At SAM we are working to build a research facility that will serve for a generation, and at the same time explore fabrication techniques that inform our understanding of how to live in a pressurized vessel.

Four hydroponics racks have arrived to Biosphere 2! These systems distributed by Hort Americas are designed for research in that they are durable, agile, and smaller than commercial racks. While we await the water pumps, plumbing assembly, and lights we got to work. New to the team William Nichols is working with us to install, test, and maintain this grow system under the expert guidance of Dr. Gene Giacomelli of the University of Arizona CEAC facility. With 200 heads of lettuce already sprouting in an incubator, we are eager to transfer the partially mature plants to SAM for the first official crop in our new, permanent system.

As the systems came with casters appropriate for a research lab or industrial floor, not the one-in-twelve slope of our stainless steel tub, we took the four bases to the University of Arizona Facilities Metal Shop and secured a 3/8″ nut to the bottom. High quality swivel feet enable us to maintain a strong, stable base over the unusual floor.