us army corps of engineers building strong ® compressed earth technology douglas s. applegate, p.e....

US Army Corps of Engineers

BUILDING STRONG®

Compressed Earth Technology

Douglas S. Applegate, P.E.douglas.s.applegate@usace.army.milProject ManagerContingency Standards BranchMiddle East District9 August 2014

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Problem Statement Populations from 20 to 60 personnel Non-permissive environment Sites are continuously occupied Minimal to no Heavy Equipment use during construction Access

► Small 4x4 vehicles due to location or security► Helicopters possible 6000#/lift► Donkeys, carts, etc► Foot

Utilities► None► Minimize petroleum use► Minimize electrical use► No WWTP► Water imported

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Requirements Amplification Site Features

► Entire site to be gravel pavement► Parking for 6 vehicles (20 man)► Exterior wall 3m high► 30m x30m nominal size► 20-60 man population

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Utilities► Water (two options)

• No well Bladder 80L/person truck filled

• Well (optional) future 2 GPM 24VDC pump Hand pump

► Sewage collection• No requirement

► Power• 30 kW Genset x2• Solar• Wind• LED Lighting• Electric water heaters (14.4 kW)

► Heat• Wood• Electric (heat and cooking)• LP (cooking)

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Requirements Amplification ADMIN/OPS

► 30 pers 480 sf► Minimum span 2m► Weapon storage 64 sf► Ballistic protected

Barracks 60 pers► 40 pers open bay► 14 two man rooms► 6 one man rooms► Wood heat

Latrine► DC rated wall heaters

Hygiene area (enclosed) ablution► 10 pers 160 sf► Gravity water w/spigots

Outdoor covered/fenced storage 400 sf

► Pole barn 4 m height minimum 2m span

Fuel point► 50 gal drum w hand pump► 2m high wall w locking gate

DFAC► 20 pers per meal shift► Wood fuel heat► Indoor food prep 180 sf

• AC electricity• Tankless electric WHs 14.4kW• Two LP fuel grills (turkey fryer)

► Outdoor food prep• Two wood fuel grills• Three walls and roof

Guard House► 2 pers 100 sf► Crew served weapons ports► Ballistic protected► One at each corner of perimeter wall

ECP Guard House► 2 pers 100 sf► Crew served weapons ports► Ballistic protected

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BUILDING STRONG®1/27/2014

Proposed Goals of TAM Solution Set Site features

► Structures contain no removable or useful pilferable materials

► No gravel on site due to weight and IED concerns

► Scalable based on population Structures

► Minimal skilled labor for construction

► Minimal imported materials► Minimize footprint► Walls are hardened earth► Roofs are metal trusses► Ballistic protection provided► Minimize weight to be transported► All materials donkey transportable

Utilities► All are man portable and

removable► Minimize petroleum use► Minimize electrical load► Water bladders► Minimize sewage collection

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Compressed Earth Blocks Blocks manufactured on site with local labor

(if available) Imported materials

► Cement► Rebar► Machines► Fuel► Water► Roof System

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Compressed Earth Blocks

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Rammed Earth

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Rammed Earth

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Proposed Design Options Exterior walls

► Constructed of masonry• Compressed Earth Blocks• Rammed earth

► Ballistic Protection• RPG net

► Utilities• Electricity - solar or wind• Heat – wood• Cooking – wood• Lighting – LED• Water – gravity fed, wood heated• Black and gray water – cess pool

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This stove weighs 35 pounds including the collapsible pipe

This stove weighs 42 pounds and has an water tank available

The Past

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This stove weighs 38 pounds and has an water tank available

This device increase the heat output of the stove and attaches to the flue pipe.

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This system weighs 125 pounds, stores 1250 Whrs and includes USB, DC 12V, AC inverter power.

The Future

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This system weighs 34 pounds, generates up to 1600W and fits on a 1.5 inch pipe

This system weighs 16 pounds

This light weighs 1.4 pounds and can charge other devices

This armor is a kevlar net with cubes of metal attached. It has been combat proven to defeat RPG’s.

BUILDING STRONG®1/27/2014

Items in Common Lighting

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This light weighs 1.4 pounds and can charge other devices

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Items in Common RPG Q-Net

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This armor is a kevlar net with cubes of metal attached. It has been combat proven to defeat RPG’s.

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Relative Construction Durations Twenty person camp – Hours per facility based on 5 person crew

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Facility Wall Area SF

CEBHours

REHours

RoofSF

JoistsHours

Admin 540 6 1080 8

Barracks 1400 16 215 2

DFAC 650 7 290 3

Guard 1280 14 80 1

Perimeter 8400 70

CEB – Compressed Earth Block 90 sf/hour RE – Rammed Earth 120 sf/hourCEB rate does not included production of blocks.

Block production is nominally 200/hour.

Surface area is 0.38 sf/block

Approximately 3 block per sf

BUILDING STRONG®1/27/2014

Parametric Cost Estimate Twenty person camp - CEB

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60 Man Camp

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60 Man Camp

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60 Man Camp

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60 Man Camp