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“Innovative Techniques in Military Construction”

House Appropriations Committee, Military Construction, Veterans Affairs, and Related Agencies Subcommittee

March 11, 2025 (recording here)

HEARING INFORMATION

Witnesses & Written Testimony (linked):

• Mr. Dave Morrow: Director of Military Programs, U.S. Army Corps of Engineers

• Mr. Keith Hamilton: Chief Engineer, Naval Facilities Engineering Systems Command

• Mr. Thomas Healy: Chief Executive Officer, Hyliion Incorporated

• Mr. Brent Richardson: Principal Research Scientist of Energy, Infrastructure and Environment, CNA

Keywords mentioned:

• Innovative technologies, 3D printing, cost efficiency, resiliency, industrialized construction, additive manufacturing, seismic zones, environmental standards, supply chain, tariffs, project timelines, infrastructure

IN THEIR WORDS

OPENING STATEMENTS FROM THE SUBCOMMITTEE

• Chairman John Carter noted that while current military construction processes produce high-quality infrastructure, they often take too long and cost too much. He cited a study suggesting that military construction costs could be as much as 35% higher than necessary and stressed the need for efficiency given current fiscal challenges. The Chairman expressed optimism that technologies such as 3D printing could improve construction timelines and costs while maintaining quality and serving military personnel and their families effectively.

• Ranking Member Debbie Wasserman Schultz raised concerns about budget cuts that she argued jeopardized veteran care, including reductions in VA jobs and the cancellation of critical contracts. She criticized the administration’s priorities, particularly the focus on cultural issues over military readiness and cost-effective construction. She underscored the importance of investing in resilient and sustainable military infrastructure, particularly in light of climate threats, and expressed hope for productive discussions on alternative construction methods.

SUMMARY OF KEY POINTS

• Mr. Dave Morrow outlined the U.S. Army Corps of Engineers’ efforts to integrate innovative technologies in military construction. He highlighted the organization’s global mission supporting military programs, research, and disaster response, illustrating the role of private industry in driving technological advancements. He discussed emerging technologies such as additive construction (3D printing), which could reduce costs and construction time, and the use of alternative materials like mass timber and fiber-reinforced polymer composites. He restated the Corps' commitment to developing resilient, cost-effective infrastructure while maintaining high standards for military facilities.

• Mr. Keith Hamilton explained the Naval Facilities Engineering Systems Command’s (NAVFAC) approach to leveraging innovative construction techniques to support military infrastructure. He described the organization’s acceleration and affordability campaign, which requires evaluating alternative construction methods at the outset of each project. He detailed NAVFAC’s use of modular construction, additive manufacturing, and advanced materials like high-performance concrete and cross-laminated timber. Mr. Hamilton also highlighted NAVFAC’s exploration of artificial intelligence to improve project efficiency and mentioned regulatory barriers that may need to be addressed to fully adopt alternative delivery methods.

• Mr. Thomas Healy introduced Hyliion’s new power generation technology, the Carnot modular power plant, showcasing its reliability, fuel flexibility, and efficiency. He described the generator as scalable and capable of operating on over 20 fuel types while adjusting automatically to variations in fuel supply. He mentioned the generator’s low noise and heat signatures, making it ideal for military applications. He credited advancements in 3D printing for making this technology viable and noted that the company had already delivered its first unit to the Navy for testing.

• Mr. Brent Richardson summarized CNA’s study on barriers to innovative military construction, arguing that the Department of Defense (DoD) needs a structured roadmap to guide technology adoption. He recommended early contractor involvement in the design process to leverage private-sector expertise and regional knowledge. He advocated for a clear demand signal from the DoD to encourage private investment in innovative construction methods. Without a formal roadmap and early industry collaboration, he warned that military construction would continue to lag in adopting cost-effective and advanced technologies.

• Chairman Carter asked about the Army Corps’ stance on 3D printing and its reliability in extreme weather. Mr. Morrow stated that 3D-printed construction is approved in low-seismic areas, with ongoing testing for higher-risk zones. Chairman Carter asked if these technologies could function in extreme heat and cold. Mr. Healy responded that their cobalt chromium components perform well in both conditions and are being tested in Alaska. Mr. Hamilton added that while additive manufacturing is advanced for parts, its use in construction is still developing, especially in cold environments.

• Chairman Carter then asked how military construction in the Indo-Pacific is addressing extreme climate conditions. Mr. Hamilton said that NAVFAC is using resilient materials to withstand typhoons, seismic activity, and saltwater exposure.

• Chairman Carter asked if 3D-printed concrete could use locally sourced materials. Mr. Hamilton responded that NAVFAC successfully tested additive construction in Guam with native materials and saltwater concrete for short-term structures.

• Ranking Member Wasserman Schultz asked how new tariffs on steel and aluminum would impact military construction costs. Mr. Morrow said that the Army Corps is improving cost estimation, but he admitted that market responses are unpredictable. Ranking Member Wasserman Schultz pushed back, arguing that cost overruns remain frequent and tariffs will increase costs. Mr. Hamilton acknowledged market challenges and conveyed that NAVFAC is exploring alternative materials. Mr. Richardson added that tariffs may push innovation but could also lead to job losses in affected industries.

• Ranking Member Wasserman Schultz inquired about military construction, resiliency, and the role of alternative materials. Mr. Hamilton said that NAVFAC is updating design standards to incorporate resilient materials and hardened utilities, especially in Guam. Mr. Morrow cited Tyndall Air Force Base as an example of improved hurricane-resistant rebuilding efforts. Ranking Member Wasserman Schultz stressed the need for continued focus on protecting coastal bases from extreme weather and saltwater erosion.

• Rep. John Rutherford discussed how multi-year appropriations could help address supply chain issues in military construction. Mr. Hamilton responded that current one-year appropriations create delays and cost increases, and allowing multi-year funding would help mitigate these challenges.

• Rep. Rutherford asked Mr. Healy whether his generator is protected from electromagnetic pulse (EMP) attacks. Mr. Healy stated that it is not currently EMP-protected but could be adapted to meet military specifications if required.

• Rep. Rutherford inquired whether the Navy plans to use new Operation and Maintenance (O&M) funding flexibility for erosion control at military facilities like Blount Island. Mr. Morrow stated that any flexibility in funding is beneficial and that recent changes to O&M rules have been helpful, particularly for barracks replacement.

• Rep. Sanford Bishop asked about the impact of a full-year continuing resolution (CR) on military construction projects. Mr. Morrow responded that without an appropriations bill, new projects could be delayed, though the current bill under consideration allows new starts.

• Rep. Bishop requested an update on the Corps’ policy of considering mass timber in construction projects. Mr. Morrow stated that a mass timber barracks project at Joint Base Lewis-McChord is fully designed and ready for execution pending appropriations. Rep. Bishop then asked about the Navy’s use of mass timber. Mr. Hamilton responded that NAVFAC is piloting a cross-laminated timber child development center in Virginia, highlighting its advantages in resiliency and precision manufacturing.

• Rep. Bishop asked about progress in eliminating PFAS-containing materials in military projects. Mr. Morrow stated that the Corps stopped using PFAS in firefighting foam in 2016 and is ready to execute final upgrades once funding is available.

• Rep. Stephanie Bice inquired about the challenges of introducing new technologies into military construction. Mr. Healy said his company initially gained access through an existing Navy contract but acknowledged that the process is complex for startups. Mr. Richardson suggested that establishing goals and metrics for the inclusion of innovative materials could help overcome these barriers.

• Rep. Bice asked whether environmental regulations increase the cost of military construction. Mr. Morrow stated that while sustainability policies can raise initial costs, they often reduce long-term costs, though this is not always guaranteed. Mr. Hamilton added that balancing initial costs with lifecycle benefits is important but acknowledged that additional flexibility would be useful.

• Rep. Bice followed up about statutory changes needed to encourage innovation in military construction. Mr. Hamilton stated that current contracting requirements make it difficult to integrate new technologies early in the design process and suggested more flexibility in awarding contracts that partner designers with constructors.

• Rep. Veronica Escobar asked what latitude installation commanders need to expand 3D printing for barracks and other projects. Mr. Morrow responded that installation commanders generate requirements, and making them performance-based rather than prescriptive could encourage more innovative solutions.

• Rep. Scott Franklin asked about statutory changes that could help improve construction processes. Mr. Morrow stated that current acquisition rules make early contractor involvement difficult and that allowing more flexibility in project requirements could foster innovation.

• Rep. Franklin asked about creating a roadmap to improve military construction. Mr. Richardson suggested a strategy similar to the National Defense Science and Technology Strategy to identify critical technologies for military construction and encourage industry collaboration.

• Rep. Franklin then asked witnesses whether power generation technology would be cost-effective at scale. Mr. Healy responded that upfront costs are higher than diesel generators, but increased efficiency and lower maintenance make it cost-effective over time, especially in military applications.

• Rep. Mike Levin asked whether there have been tests of larger 3D-printed barracks. Mr. Richardson stated that current technology limits 3D-printed concrete to single-story buildings, but mass timber could allow for multi-story construction. Rep. Levin mentioned structural reinforcement, and Mr. Morrow confirmed that 3D-printed concrete is reinforced with steel but requires more testing for multi-story use.

• Rep. Levin discussed alternatives to 3D printing for barracks at Camp Pendleton. Mr. Hamilton suggested industrialized construction, where prefabricated modules are manufactured offsite and assembled onsite, which could accelerate the Marine Corps' long-term barracks replacement plan.

• Rep. Nick LaLota asked how the military could improve infrastructure in the Indo-Pacific region. Mr. Hamilton suggested using industrialized construction to fabricate components in the U.S. and ship them to overseas installations for faster deployment.

• Rep. LaLota then asked how Congress could help the military complete construction projects on time and within budget. Mr. Richardson stated that identifying and implementing new technologies could improve construction performance and efficiency. Rep. LaLota inquired about reducing bureaucratic delays, and Mr. Morrow said the Corps is identifying legal, regulatory, and policy barriers that drive up costs.

• Rep. Michael Guest asked how Congress can support ERDC’s research mission. Mr. Morrow responded that ERDC operates on a reimbursable basis and needs specific legislative authority and appropriations for its research initiatives.

• Rep. Guest followed up on how new construction methods can apply to both new builds and renovations. Mr. Hamilton stated that integrating new materials is easier in new construction but that some technologies, like reinforced polymers, can extend the lifespan of existing structures.

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