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#1 Yesterday 15:28:31
- SpaceNut
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- From: New Hampshire
- Registered: 2004-07-22
- Posts: 30,201
KBD512 Biosphere structure of cast basalt
SpaceNut,
I was thinking of using a combination of 304L from the expended Starships and indigenous materials in a "space frame" design wherein the Starship steel provides external structural support so that locally-sourced cast basalt tiles interlock into the space frame and are pressed outwards and into the space frame by internal pressurization, with sealing accomplished using either a thin internal layer of stainless sheet steel welded into the space frame, over the top of the inner tile faces, or a Silicone-based adhesive sealant could also be used. We can bring enough 304L and Silicone sealant from Earth to build this kind of structure by scrapping / recycling the Starships. I don't think it's feasible to bring enough concrete or basalt tiles, hence why that material must be locally sourced.
Do you remember the structure of the "Biosphere 2" built in Arizona?
So, imagine that we create a giant ring-shaped habitat, rather than a Super Dome, so as to keep tensile stresses sane, so as to economize on recycled steel, so as to allow us to safely use cast basalt tiles without the thickness of said tiles needing to greatly resemble the stones used to build the pyramids. This maximizes internal volume, minimizes material consumption. We can still build a Super Dome from locally sourced meteorite Nickel-steel, but for sake of argument presume that we can only handle local production of indigenous liquid water, atmospheric gases, and one construction material that we only have to melt and cast into a limited number of molds. More could always be done using more equipment and labor, but we have to bring those things with us.
This is the building that has the stepped shape.
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#2 Yesterday 15:29:41
- SpaceNut
- Administrator
- From: New Hampshire
- Registered: 2004-07-22
- Posts: 30,201
Re: KBD512 Biosphere structure of cast basalt
Framing for glass or in this case cast basalt panels.
The Mars cast basalt manufacturing process involves melting Martian basalt/regolith in a furnace (around 1200-1500°C), pouring the liquid rock into molds to form shapes like bricks, pipes, or tiles, and then carefully cooling (annealing) the cast product in kilns to control crystallization, eliminating internal stress and creating durable, wear-resistant structures for planetary habitats.
Key Steps in Manufacturing Cast Basalt for Mars
Raw Material Preparation: Basalt rock or Martian regolith (soil) is collected and processed.
Melting: The material is heated in an electric furnace to a molten state, typically around 1200-1500°C, similar to terrestrial glassmaking.
Molding: The molten basalt is poured into molds to create desired shapes, such as bricks, tubes, or structural components.
Annealing (Controlled Cooling): This crucial step involves slow, controlled cooling in a kiln over many hours, often from high temperatures (e.g., 800°C) down to lower ranges (480-520°C) and then to room temperature, to prevent cracking and develop optimal strength.
Finishing: Products can be used as-is or further processed, like being lined with cement grout for enhanced durability.Why It's Ideal for Mars
In-Situ Resource Utilization (ISRU): Uses readily available Martian basalt.
Durability: Creates hard, strong, abrasion-resistant, and chemically inert materials.
Versatility: Can form building blocks (bricks, beams, columns, domes) and structural reinforcements.
Energy Efficiency: Basalt melts at relatively lower temperatures compared to some metals, making it suitable for solar or nuclear-powered Martian systems
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