Constructing a larger settlement - One idea

Bill White · 2004-06-13 22:37:41

One idea for building a larger settlement would be to use robots to dig a sufficiently deep trench. Large tools would need to be delivered by separate launch from Earth.

If a solar ion tug existed that could spiral http://www.ditchwitch.com/dwcom/Equipme … 4#Top]this thing out to L1 for a lunar fly-by then an Earth fly-by then off to Mars, it appears that a single Proton launch would be sufficient to deliver the mass to Mars. http://www.ditchwitch.com/dwcom/Categor … /1009]This is a nice attachment for cutting deep. Maybe design a custom trencher that can go 3 to 4 meters deep.

$75 million for the launch, plus the cost of using the solar ion tug (a nuke thermal tug to move cargo to L1 and accelerate that same cargo along the Lo Road to Mars would be even better), plus the cost of the dozer/trencher itself plus the landing system. Well under $400 million, IMHO.

Power with an internal combustion engine and burn methane/LOX made by your Sabatiers. Plenty of power when need to punch through tough regolith with diamond tipped saws. The Rocket Company fictional book asserts that MobilOne synthetic oil would work just fine in vacuum on the Moon.

If true, an off the shelf John Deere converted to methane burned with LOX and a system to recover all of the H20 combustion by-products would not seem to require rocket science.

Then dig a narrow trench 3-4 meters deep and 40 meters long and less than 1/3 meter wide. Dig an identical parallel trench 3-4 meters deep about 8 meters away. Looks like railroad tracks.

Okay your dozer just spent one hard day at work.

The next day cross cut to the same depth as many perpendicular cuts as seem necessary. Turn your dozer around and http://www.ditchwitch.com/dwcom/Categor … 07]backhoe out the chopped up regolith.

Repeat as needed until you get down maybe 8 meters. An extension arm on the saw blade and a ramp down into the trench would be useful. You could also terrace your way down. 18 meters wide and 2.0 meters deep. Then 15 meters wide and a total of 4.0 meters deep at the center. Then 12 meters wide and 6.5 meters deep at the center. Then 9 meters wide and 9.0 meters. Then you stop.

Spoil can also be mounded on top to reduce the depth you need.

Reinforce the trench walls as needed. Thin aluminum sheets reinforced by trusses run across the trench might be one idea.

The assemble one of http://www.mi-jack.com/travelift/travel … .jpg]these things from lightweight aluminum trusses also shipped from Earth. This can be assembled "tinker-toy" or "erector set" style and should not weigh nearly as much as the dozer. If a tug existed to get to L1, a single Proton would be well more than adequate.

Just make sure your span exceeds the width of the trench. If you went the terrace route, build a ramp down to a suitable terrace level.

Then use the straddle crane (called travel lifts in boatyards) to deliver http://www.ilcdover.com/SpaceInf/habita … .htm]newly delivered uninflated TransHabs into the trench.

Inflate after positioning. Interconnect the TransHabs. Then backfill, making sure each TransHab has a central core escape hatch above the surface.

Leave one side of the trench open with a ramp up to the surface and voila! a habitat for a few dozen people. Excellent radiation shielding, thermal installation, protection from micro-meteorites and weathering.

Repair the fabric from the inside.

Not all that expensive, either.

= = =

I submit that a team of four or six astronauts could build such a thing in less than 10 weeks on Mars, if all materials were pre-positioned within the reasonable vicinity of the construction site, and a trailer was included with the dozer (or with the travel-lift shot) to haul materials and the Transhabs from where they land.

Two Proton launches; X launches of empty, uninflated, crewless TransHabs; one Mars Direct mission and you can build a permanent settlement awaiting colonists, supplies and as many nuclear reactors as the settlement authority can beg, borrow, buy or steal.

= = =

Build this remotely and robotically from Earth? Wait many decades (or more) until robotic technology improves by many, many generations.

Rxke · 2004-06-14 01:37:39

Bill,
Inspired by KSR's Red Mars Underhill design? It sounds very similar, in essence. IIRC they also use a John Deere, complete with backhoe...

I thought KSR's design was too much work, even for a 100 person crew, if you want to dig in *fast*... But definitely a good design if you're not in too much a hurry (there to stay)
Your inflatable hab design would make it a lot less work-intensive, very good point.
KSR's design has it's merits, in the long run in that it uses virtually 100% on-Mars-manufactured building material, no need for launching inflatable habs. Good design if you already have a primary living-space.

I myself am always dreaming about an automated tunneling machine, let it dig into hills, even years before permanent residency, (serviced maybe by first temporary landing parties) add some airlocks, and presto, an ever growing maze of pressurisable tunnels, outfit them as the need arises... Downside to that is: equipment weight is waaaay above current launch/landing capabilities, it would take some extensive exploriation efforts to find a suitable location to start digging etc...

geo_flux · 2004-06-14 02:18:25

I've always been in favor of doming over a small canyon. That way all the hard digging is already done and all you have to do is add a durable roof.
Even better would be to use a large lava tube ala KSR (I think). All you have to do that way is add an air lock in the opening and your done.

Rxke · 2004-06-14 02:41:50

Both those things will be done, eventually, but the several first missions won't have the manpower/hardware on the ground to do such 'big' things, i'd recon...
The lava-tubes are interesting, *if* they prove to be suitable, but answering that question will take quite some time exploring, probing etc. Probably work for precursor rover missions...

Shaun Barrett · 2004-06-14 08:37:56

Dr. Zubrin came up with a similar plan involving inflatable spheres.
The idea was to dig a hemispherical hole, place the inflatable sphere in it, inflate the sphere, and put the regolith back inside the lower half of the sphere via the airlock. Since the atmosphere-retaining material is in the shape of a sphere, there's no problem with internal pressure lifting the resultant dome off the surface.
Josh and I discussed this at some length and modified the idea slightly. We suggested placing the sphere in the hemispherical hole in the ground (an impact crater of suitable dimensions would save a lot of excavating) but, instead of putting all the dirt back inside, construct a few floors using aluminium beams and sheeting and use some of the dirt to make a, say, 2 metre regolith shield on top of the uppermost ceiling.

Looking at your excavation above - 40m by 8m by 8m - you're moving 2560 cu.m of regolith.
Even if we can't find a suitable crater in the area, meaning we have to dig out a whole hemisphere of dirt, a similar effort means we can situate a sphere of about 21m in diameter. (a total excavation of 2425 cu.m)
Assuming we wish to occupy the lower half of the sphere, we have a hemisphere with a radius of 10.5m in which to build floors ... minus the 2m of soil to be placed on top of the uppermost ceiling.
Thus we have a height of 8.5m available for floors. I would suggest 3 floors in this case, each of about 2.65m vertical dimension - about 8'8" in the old money! Obviously, the lowest floor would have the least useable space because of the walls of the sphere and might become the storage area.
In the middle, there could be a cylindrical open space for an elevator and/or ladder, and to provide a degree of natural daylight down into the living areas. A translucent water tank above the open space might stop radiation but allow visible light through.

The advantage with this idea is that you also have a clear dome above ground covering nearly 350 sq.m of regolith, in which you can have a livable atmosphere. The 2m of soil deposited on top of the living levels can also be fertilised and used to grow crops. Wearing only a Demron suit and hat, the colonists could tend to their crops 'out in the open', so to speak - a big psychological plus.

Waddya think?
???

MarsDog · 2004-06-14 12:03:28

No use going big and inviting a catastrophe.
Number of closely located redundant modules first, and then after the area is well understood, the economy of scale might dictate large esthetic structures.
-
Have any lava tubes been located ?

Bill White · 2004-06-14 14:15:38

No use going big and inviting a catastrophe.
Number of closely located redundant modules first, and then after the area is well understood, the economy of scale might dictate large esthetic structures.
-
Have any lava tubes been located ?

Depends on who you are.

Settling Mars is rather like a Dutch auction.

As technology improves, the cost and risk decrease.

Whichever subset of humanity chooses to go first and settle first will find themselves on the ground floor of the greatest expansion in all human history.

Shaun Barrett · 2004-06-14 18:53:16

I think Bill is right!
If we're sending a Hab, a fuel synthesiser, and a nuclear reactor to Mars in advance of the people (a la Mars Direct or similar), an earthmover and maybe a few tonnes of aluminium with an extruder would surely be well worth the extra launch.
The reactor will be producing a lot of heat as well as electrical power and could be pressed into service to soften aluminium. With various extruder 'profiles' (sorry, don't know the proper terminology), many useful structural members could be fabricated in situ.
Some kind of reinforced polymer sphere of a suitable size needn't weigh a vast amount and, in deflated form, would be quite compact.

Nobody here wants a 'flags and footprints' fate to befall Mars exploration. Bill's plan constitutes thinking ahead and makes perfect sense to me.
Far from "going big and inviting a catastrophe", the more technology the astronauts/colonists have available to them, the less chance there must be of a disaster occurring.

Just an opinion.

Bill White · 2004-06-15 05:40:03

Well, why not? The bitch about MarsDirect is the mass budget.

Fair enough, I can concede that. Its a bare bones flight. But you can pre-position stuff with cheap Russian and Ukrainian boosters. Lots of stuff.

Going forward, one nuclear thermal tug to push stuff from LEO to L1 then to a lunar/Earth fly-by to Mars, with the tug braking rather than accelerating after the cargo is cut loose for return to LEO greatly increases our ability to throw stuff to Mars.

Logistics. Its all about creating a logistical pipeline to support the settlers.

Dook · 2004-06-22 10:54:55

I really like Zubrin's sphere idea, put it in a crater, fill with regolith, then inflate. Building living levels is also a good idea but if there is not a suitable crater in the area you wish to build then that is a problem. You could dig your own crater I suppose. Also it would provide little insulation from mars extreme cold. You would have to have heating units on full time.

I think the best idea for building on mars is still bricks. After a few mars habs have landed we could send up one devoted to making bricks. A soil scoop could be mounted on the front of the mars trucks, or pressurized vehicle, could deliver soil to the brick making hab that would then sift the soil, add water and mix, pour the solution into molds, bake and recover the water. The most arduous part would be physically laying all the bricks in place for the walls and floor of the walls but the center could be used to grow food with maybe a pyramid shaped skylight above.

Dook · 2004-06-22 13:45:19

Another problem with bricks is that you have to keep them in compression. Not sure if you could build a roof with them or a floor for a second story.

For the inflatable sphere, what if you had 2 separate spheres? The inside one pressurized the most, second one maybe a 3 foot gap and pressurized a bit less. They could be put together before launch then carried by the mars truck to the crater. An external compressor could be hooked up to pressurize both spheres with mars C02 then bring the soil into the center sphere. After the soil is in either a liquid oxygen tank could be brought in and vented or maybe those machines that make oxygen from C02 to oxygenate the inside. Then bring in fertilizer, water, and plant seeds. You could have a tube going down through the soil inside to collect irrigation water and re-use it. Two layers would provide insulation from mars cold temperatures as well as provide a double air lock.

Shaun Barrett · 2004-06-22 20:28:52

Hi Dook.
I've never been able to work out how bricks could be used in the hostile building environment Mars presents us with. Any habitat we make will be essentially like a potential bomb - threatening to explode outwards at any moment due to the pressure inside. Even a minimal 350 millibar atmosphere inside a habitat will result in over 3 tonnes/sq.m trying to get out!
Persuading bricks and mortar to hold together under those circumstances seems an impossible task. And how can you mix and apply cement in a freezing virtual vacuum and get it to set properly in the first place?!
???

Some time ago, here at "Life Support Systems", on page 3, we discussed building techniques at some length under the headings of "We need a brainstorming session" and "Domed habitats .. " (especially the latter heading).
You might care to have a look at the posts there and then give us your views on what can be done(?). My opinion is that we'll need either completely new techniques of construction or we'll need to use old techniques within the protective confines of pressurised spheres etc.
Any thoughts?
???

Bill White · 2004-06-22 20:51:20

http://www.space.com/scienceastronomy/s … .html]Mars bricks can be made from regolith with a polyethylene binder perhaps doped with boron.

Once a brick structure was created and before pressurizing, line the interior walls with TransHab fabric then pile regolith on top for weight. In essence, bury your brick structure.

= = =

Uniform bricks could also be used to form walls in a trench then backfill around the trench exterior before adding atmosphere. The weight of the regolith holds the atmosphere in.

= = =

Build brick houses inside a pressure dome. The dome holds in the atmosphere and the brick house protects inhabitants of the houses. Walking between houses is done at settlement normal pressure yet exposes settlers to higher radiation levels.

= = =

Edit: Regolith, whether lunar or on Mars appears low in hydrogen. Thus not a very effective radiation shield. Huge mounds will need to be piled up unless it is bound together with polymer.

http://www.lauralee.com/news/marsbrick.htm]Another link

MarsDog · 2004-06-23 08:25:37

Eskimos build igloos out of ice blocks.
A similar structure could be sealed and pressurized.
-
A large settlement construction project will need a lot of electrical power.
-
With enough power you could just melt rock, blow CO2 into it and create pumice. Pour the molten rock, as it is made, a little at a time, and use moveable forms similar to reinforced concrete high rise construction.

Dook · 2004-06-23 11:05:06

After reading through the previous posts of this topic I think I've changed my mind regarding the use of bricks. I was impressed with the pictures of the brick design habitat made by Captain Rich but it was clear to me that it was just too much work. The structure required thousands of bricks and a lot of mortar. While it is possible it just seemed inefficient compared to the idea of simply using an inflatable dome.

Edited 24 June:
Some of the posts were concerned with dome punctures but I think this is an extremely rare risk. The main concerns are pressure loss through the fabric (clear mylar?) and how to keep it warm enough inside. What if you had three inflated spheres, center, middle, and outer sphere with the inside one having 5 psi air atmosphere, the second sphere pressurized to 2 or 3 psi ozone for absorbing dangerous UV, and the outer sphere pressurized to 5 psi with sulfur-hexaflouride or some other super greenhouse gas? Not sure exactly how much this would help retain heat or if it would damage the dome material. I think the domes should be as transparent as possible to take advantage of the lighting effect to help grow the plants.

Maybe assemble them in an octagon pattern with one in the middle and connect them all with tubes. The regolith brought in to fill the first one's floor would make the crater for the second sphere and so on.

Dook · 2004-06-24 14:15:00

Another idea for making craters rather than having to dig them out would be to use explosives. Dig a hole and place a charge in to artificially make a crater to put the spheres in.

Grypd · 2004-06-24 16:41:59

There where a couple of other means I had looked at to burrow into the ground on mars and the moon.

If as we think we have found that mars has a strong permafrost level under the soil simple digging in reduced gravity would be a lot more difficult.

1) It may be possible to burrow a series of pipes into the ground and using super heated gas or steam, these could be pumped into the area to be excavated. The ground would be broken up and allow more traditional ways of excavation without the needs of explosives. The water that is released could be pumped out. Of course heating the element to be pumped in could be done by using some of the waste heat from the mars direct chemical reactions.
2) On the moon/mars the gravity is reduced and the material is of a threat to automation this is fines that will form a corrosive dust cloud. It may be that as a vehicle will be unable to use weight to take the materials up it could, Using brushes like a street sweeper, sweep the material in for collection.

Ian Flint · 2004-06-26 10:01:31

Here's an idea for a habitat that has both redundancy in case of loss of pressure and plenty of open pressurized space.

The core component of the habitat would be a torus made out of kevlar or some kind of ripstop plastic. This donut shaped structure has the same pressure containing benefits as a sphere but has less volume for the same amount of floor surface area (when filled half full of regolith). So the torus could be made thicker and heavier than a half buried sphere of equal floor space.

So you start by digging a big ring to lay your torus in. Remember that compared to a sphere you will have to remove less dirt. Then you fill the donut half full to make your floor. Before or after filling it you could build some brick shelters in the lower half of the torus (underground). These could be regular living spaces or just emergency shelters in case the torus springs a leak. After covered with dirt they would also have a measure of radiation protection.

So now you have the basic habitat design. The torus can grow crops in it and you have shelters underground inside the same torus.

Now for some R & R you can erect a dome to cover the whole torus. I think a relatively thin torus with a large "hole" in the center would be perfect. The dome could be erected over the whole thing with a few meters of space between the outer rim of the torus and the skirt of the dome. This way the torus could be repaired in a shirt sleeve environment. The dome could be (and probably will have to be) made of much more flimsy material because it will have so much more surface area (a.k.a. mass). But this shouldn't be a problem as long as the fabric won't tear or pop like in KSR's trilogy. If there is a leak people can just head to the torus. The "hole" in the center would become a large park. Under the dome only nonessential plants should be grown (grass, trees, shrubs, etc.). The torus would house the food crops.

So, you can start with just the torus; build underground shelters inside it at the same time or after the torus is up and running; then, when you need more elbow room you can enclose everything in a big dome.

With each addition you get more (and a better variety of) living/playing space while at the same time adding more levels of safety.

Bill White · 2004-06-26 10:18:46

Ian, I see no reason why TransHab fabric could not be sewn into whatever shape you wanted.

A torus sounds excellent except for the need to sew all the parts together unless it could be shipped in one piece. (I am looking at my kid's swimming pool inner tube right now and it does seem an ideal shape!)

IIRC TransHab fabric can be 12 inches thick, or more, when expanded. Perhaps it can be compressed (and de-compressed) and vacuum packed for shipment to Mars.

Then unroll and inflate.

Include aerogel layers and boronated plastics along with layers of kevlar and include air pockets or water bladders as part of the 12 inch thick fabric.

Rather like a hi-tech fabric "Dagwood" sandwich.

= = =

For torus #1 I might suggest hydroponics because Marsian regolith very likely has nasty stuff in it, perhaps including heavy metals.

IMHAO (humble amateur opinion) seeds stuck in regolith and then watered will merely die, or worse, incorporate heavy metals into the plant matter.

Set up a regolith processing plant to screen out heavy metals and balance the pH and then mix it into plant waste and processed human waste and then we can start formulating Marsian soil.

Regolith ain't soil. Soil requires a staggeringly complex suite of Terran micro-organisms.

= = =

Water storage might well be in tubes sewn into the ceiling run around the entire torus. A nice added radiation shielding.

= = =

Why dig? Just plop it into a crater and inflate. (Okay, smooth the surface first) :;):

I guess digging some tunnels first makes sense, then deploy the de-flated torus in the crater on top of the tunnels.

= = =

Inflate the torus to 50% of Terran sea level pressure maybe with very slightly elevated oxygen partial pressures to best tune the gas mixtures for optimal human respiration.

Inflate the outer dome to 25% of Terran sea level pressures and mix gases that are best suited for plant respiration.

= = =

Ian, find some investors, hire Constance Adams (a TransHab architect) and start sewing TransHab fabric into whatever shapes you want.

The big torus will cost you $XYZ but I have the intermediate model at 25% off list price. . .

If you need added radiation protection, hang plastic/boron radshield tapesties inside the torus, and if your torus is big enough to allow two or more levels, people sleep on the ground floor with storage on the top floor.

Rxke · 2004-06-26 14:00:18

Nice idea, Ian.

For making it super-duper-extra failsafe, you could segmentize it easily to boot. When there's a leak, just close inner airlocks, and majority of structure is still airtight. Much harder to do that with a dome...

Come to think of it, i love the idea... different subsections could have different atmospheric mixes, for a very quick testing of adaptability of plants, mosses, higher life etc...

Hmmm.. But before I get too exited: how big could such a structure be, 'hole' diameter, tube- radius etc.. if it's too small, it's fairl worthless, but you could launch subsections and connect them, (airlock-wise)

Say four complete a full circle, fifth launch brings the dome fabric...

Bill White · 2004-06-26 15:36:03

I am thinking of a tube with an internal 8 meter radius (25 feet for us US-ians).

How big around does that made the entire thing? (I guess that depends on how big or small you make the donut hole.)

With 25 feet of interior space, you have three levels or floors. Storage on the top level to aid radiation protection.

It cannot be sent fully assembled, obviously. Send it vacuum packed and compressed as much as is feasible.

Interior fitings are added after inflation. Interior doors, alloy (or plastic) stairs and ladders; furniture, etc. . .

I have long visualized water and air filled plastic furniture. Easy to ship, all rolled up, and then just fill with a few inches of water for weight and stability and air to finish the job.

That also allows storage of reserve water, you sleep on it every night.

And the exact same inflatable furniture can be sold on Earth with profits going to help fund the setlement.

Edit: If we can accept various diameters for the internal tube, you can collapse the thing for shipping, like a telescope.

8 meters for X distance, then 7 meters, then 6 meters. Before launch the 6 meter section slides into the 7 meter section, then they both slide into the 8 meter section.

Any origami experts?

Grypd · 2004-06-26 16:05:09

Could extensions to that initial inflatable base be made on mars using insitu materials like martian fibreglass.

Certainly using the metals furniture etc could be made and structural supports.

Ian Flint · 2004-06-26 18:40:36

I was originally thinking of a transparent torus a few mm thick, but I like the idea of using 12 inch thick transhab material -- very robust. If we're growing plants in the torus, it needs to let plenty of light in, of course. I don't know how transparent a transhab structure can be made.

This would only be feasible for the first few missions, though, because of the mass involved. As larger and larger toruses are used, the walls will need to either be very thin or manufactured on Mars.

I still contend that shelters should be buried under the ground level of the torus. The benefits of this are: radiation shielding, redundant pressurized living space, and more room in the sunlight for growing crops.

About Crops:
I agree that hydroponics or other highly controlled methods should be employed on Mars. In the torus I envision racks stacked as tall as necessary growing everything possible for the colony/base. Mirrors should be employed and the racks should be staggered to share the incoming light efficiently. The racks could have reflective bottoms to give those beneath a little extra light.

Outside the torus under the dome (which would be a half sphere, staked into the ground around the edges) they should try to grow plants in the regolith with as few modifications to it as possible. Since nobody will eat what grows under the dome, there is no health risk. (Oooo...except pollen. Can you imagine pollen laced with heavy metals. Talk about bad allergies!) With minimal soil modifications plants can propigate faster (in a more Mars-like environment -- prelude to terraforming) and we can study how and if they can make the soil suitable for crops.

So here you go:

1. One torus with strong, transparent, transhab-style walls maybe an inch thick.

2. Living quarters buried underground inside the torus.

3. Hydroponics employed above ground inside the torus.

4. A dome a few mm thick surrounding the whole thing. This dome is optional and can be delivered years later.

BTW, years ago I think NASA did a study on this shape for a lunar base. It was small kind of like transhab. They were thinking of putting a drill in the "donut hole" to lift Moon regolith to the top of it and then just let it pile up and cover the torus for radiation shielding. I'm sure this came up on this message board before.

Grypd · 2004-06-26 19:10:10

Have you considered instead of making the top half of a dome transparent with the reduced Radiation and heat insulating properties just have the one window this being at the top.

This way you could using sandbags or similar of martian Regolith and insulate and protect the majority of your dome.

Getting natural light into the dome would be accomplished by the use of mirrors that circle your dome and reflect the light towards the top and this light is then focused and reflected inside through your one open window.

Other windows to the outside could easily put on the side of the dome but these would routinely be closed and have a form of storm cover.

The advantage to this system is less digging into the ground is needed. The regolith sandbags provide decent radiation and puncture cover whilst providing weight to the structure. The light coming into the dome can be controlled allowing improved yields of crops grown. And the domes as they do not require large quantities of Hi Tech radiation proof transparent material can be made by the martian bases.

Ian Flint · 2004-06-26 19:36:23

That is very functional, but I think the colonists would like to be able to see broad vistas in every direction. The torus could be covered with sandbags, I guess. I just don't know which would be more efficient (for growing crops and heat insulation, etc.) -- small windows, mirrors, and sandbags, or transparent walls and heaters?

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Re: Constructing a larger settlement - One idea

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