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The U.S. Army is taking a giant leap into the future of military construction with the debut of its first-ever additively constructed (3D-printed) Army barracks in Fort Bliss, Texas, and the U.S. Army Engineer Research and Development Center (ERDC) played an important role in making the demonstration successful.
Experts at ERDC’s Construction Engineering Research Laboratory (CERL) in Champaign, Illinois, have unique expertise in additive construction, and the team was brought in to review the walls of the 3D-printed structures, ensuring they met safety and quality standards, while staying in compliance with the Unified Facilities Criteria (UFC) language on additively constructed concrete, allowing for the use of this technology in Department of Defense (DoD) construction.
The UFC is a compilation of DoD documents that define items for ensuring that completed construction of any kind performed by or for the department of defense is safe for all occupants or users, whether civilians, service members, or generals and above.
“Additive Construction (AC) is relatively young compared to conventional construction, which often relies on historical data for design and performance,” explained Megan Kreiger, Portfolio Manager of AC at ERDC-CERL and the DoD AC subject-matter expert. “Since AC lacks this longstanding historical data, it is important to fill this gap through proper evaluation and understanding from a performance and design standpoint.”
In 2023, ERDC and the Tri-Service UFC structural discipline working group drafted UFC 3-301-01 Section 2-7.2 1903.5 to outline uses, limitations, testing requirements and submittals for the newly constructed barracks. This effort is a breakthrough for AC, as it is the first building in the world to go through an extensive review process specific to the technology and meet the overall UFC.
“ERDC has worked to develop, understand and push the limits of additive construction for both expeditionary environments and installations,” Kreiger added. “The collaborative effort with private sector and the Army on the 3D Printed Barracks project was a significant step towards tech transition of AC.”
These pioneering barracks represent the first large-scale use of 3D printing technology in military infrastructure. Designed to house up to 56 Soldiers, the barracks highlight how 3D printing could be used to build energy-efficient and resilient buildings. The project is the largest of its kind in the Western Hemisphere, with each building spanning more than 5,700 square feet.
At the request of the U.S. Army Installations Management Command, ERDC reviewed and analyzed multiple submittals for three buildings, such as descriptions of mixtures and performance, design drawings, quality assurance and control narratives, design calculations, third-party testing reports and structural stability assessments. ERDC’s evaluation also covered test results from shake-table testing and pseudo-static tests, comparing these results with quality control data and design requirements. Additionally, ERDC analyzed the construction process in detail, reviewing operational logs, construction conditions, and the material properties by layer throughout the printing process, alongside a site condition assessment of the walls.
“This innovative pilot program marks a significant milestone for the field of AC as the first structures to undergo a rigorous review process thorough testing and evaluation prior to occupancy and has the potential to modernize infrastructure through resilience for Army installations,” Kreiger said.
ICON, a construction technology company based in Austin, Texas, was selected to complete the barracks pilot construction. Three buildings were opened in the proximity of Fort Bliss, two in the Pershing Heights area and one at Camp McGregor on the Fort Bliss Training Complex in New Mexico.
“ERDC-CERL provided oversight and review for the 3D-printed wall systems during the development and construction of the new barracks, leveraging their expertise in research and innovation to advance construction technology for the Army and DoD," said Bella Nowland, ICON's Associate Director of Business Development. "The new 3D-printed barracks represent the first-ever structures to meet Pentagon's Unified Facility Criteria for additively manufactured buildings-a remarkable achievement. Together with the DoD, we look forward to continuing to advance ICON's R&D and technology suite to expand the possibilities in military infrastructure."
The collaboration between ERDC-CERL and ICON has been key to bringing this innovative vision to life. ERDC-CERL has been at the forefront of additive construction research since 2014, working alongside the DoD, academic institutions and private sector partners to address the unique needs of military construction.
As the U.S. Army explores the future of construction, expertise from ERDC-CERL in additive manufacturing has been instrumental in shaping the successful development of these state-of-the-art facilities. The project was completed in partnership with the Fort Bliss Garrison Directorate of Public Works and the U.S. Army Corps of Engineers (USACE), both of whom played a crucial role in securing the safety certifications for these privately constructed buildings.
"USACE is a public engineering organization that provides engineering services to the U.S. military and the nation,” said Chris Thompson, chief of Military Engineering at USACE. “ERDC-CERL enables that mission by thinking beyond this project, developing criteria, engaging industry partners, and supporting testing that will unlock additive construction to huge swaths of the country and military purposes all over the world. This visionary leadership, sets the example of how bold research and development is a force-multiplier for the Army.”
As the Army explores the potential of 3D printing, ERDC ensures this innovation meets the highest standards of life safety and structural integrity. By thoroughly reviewing and validating the designs, ERDC has played a key role in making sure these barracks not only meet, but exceed safety and durability requirements. ERDC is helping shape a new era in military construction, where innovation aligns with the Army’s commitment to Soldier welfare and mission success.
| Date Taken: | 02.26.2025 |
| Date Posted: | 03.04.2025 12:10 |
| Story ID: | 491543 |
| Location: | TEXAS, US |
| Web Views: | 34 |
| Downloads: | 0 |
This work, ERDC plays critical role in review of first 3D printed Army barracks, by Sophia Espinosa, identified by DVIDS, must comply with the restrictions shown on https://www.dvidshub.net/about/copyright.
