Project Highlights

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Additive Manufacturing Application for Soo Locks

Why it matters: Additive manufacturing accelerated fabrication turnaround time by 10X

The U.S. Army Corps of Engineers faces challenges maintaining aging infrastructure, including critical systems for navigation and flood risk management. To address this, the U.S. Army Engineer Research and Development Center (ERDC) used large format additive manufacturing (LFAM) to quickly produce a 60-year-old lever arm replacement for the Soo Locks. Traditional manufacturing had an 18-month lead time, but ERDC partnered with USACE and industry to use arc-directed energy deposition (arc-DED) to fabricate the lever arm in just 12-14 weeks, avoiding a shutdown and saving $6.1 million per day. This became the largest U.S. civil works component made by additive manufacturing, showcasing the technology’s potential for aging infrastructure.

Using Biopolymers to Strengthen Earthen Levees & Dams

Why it matters: Biopolymers provide a cost-effective solution that can help to mitigate risk and ensure robust flood control embankments.

Earthen levees and dams, often made from locally available soils, may struggle to maintain vegetation, leading to increased erosion and breach risks. Traditional vegetation-based erosion control is costly, while petroleum-based polymers can leach toxins into the soil. To address this, the U.S. Army Engineer Research and Development Center (ERDC) is studying biopolymers to enhance erosion resistance. Biopolymers improve vegetative growth, root density, and soil strength, boosting stability. Experiments on full-scale embankments show biopolymers as a sustainable, cost-effective alternative for long-term flood control.

DamBot™ Extends its Reach: Autonomous Robotic Arm Enhances Safety During Inspection

Why it matters: The robotic arm offers a strong ROI through increased inspection coverage, reduced labor hazards and optimized infrastructure reliability.

The U.S. Army Corps of Engineers (USACE) manages over 700 locks and dams, many of which are aging and require regular inspections. To reduce risks, the DamBot™ system was developed to inspect hazardous environments remotely. Enhanced in 2021 with a 16.5-foot robotic arm, it allows closer inspection of critical areas and supports nondestructive testing. With a median dam age of 57 years and many exceeding their service life, traditional inspections pose safety risks. DamBot™ eliminates these by performing autonomous, remote inspections and has been deployed on over 10 USACE projects, improving safety and efficiency.

3D-Printing for Innovative Ecosystem Restoration & Natural Infrastructure

Why it matters: Transforms dredged sediment into resilient infrastructure that supports coastal resilience.

This research aligns with USACE goals in coastal resilience, habitat creation, and sediment retention by using 3D printing with natural materials like dredged sediments. This method creates nature-inspired structures that support nutrient capture sequestration, habitat restoration, erosion control, and flood risk management, contributing to the goal of using 70% of dredged material by 2030. Unlike traditional manufacturing, 3D printing enables custom, resilient designs, turning sediment waste into a valuable resource. ERDC's pioneering efforts in 3D-printing habitat structures have successfully supported marine species colonization and advanced coastal infrastructure solutions.

Risk-Based Prioritization of Operational Condition Assessments

Why it matters: millions in maintenance funds could be reallocated to facilities with a higher risk

USACE manages over 700 dams and 4,000 miles of levees, using the Operational Condition Assessment (OCA) system to evaluate components every five years. However, OCAs lack a comprehensive risk assessment to identify preventable high-risk failures. A new risk-based prioritization framework is being developed to better assess facilities and prioritize resources. With 70% of flood risk management (FRM) dams exceeding their service life and 35% in poor condition, this methodology calculates failure probabilities and consequences, enabling more efficient resource allocation and improving dam assessments, maintenance schedules, and investment prioritization.

Large Format Metal Additive Manufacturing for Civil Works

Why it matters: LFAM can accelerate manufacturing of critical infrastructure components by 10 times

USACE faces challenges maintaining aging infrastructure, especially as replacement components become scarce. Traditional manufacturing methods like casting and forging are slow and costly. Large format additive manufacturing (LFAM), using techniques like arc-directed energy deposition, enables faster, cost-effective production of large metal parts. LFAM can reduce downtime by quickly fabricating critical components, speeding up manufacturing by up to 10 times compared to traditional methods. This technology also allows for modernizing designs and materials, improving infrastructure maintenance and enabling rapid replacement part production.

Learn more at https://poweroferdcpodcast.org/advanced-manufacturing/

Hurricane Evacuation under Compounding Threats

Why it matters: Advanced tools for smarter hurricane evacuation and faster, safer response to compounding threats.

Hurricane evacuation planning is complicated by interactions among stakeholders and infrastructure networks, often ignoring compounding threats like road disruptions or pandemics. USACE R&D is developing advanced modeling techniques, including agent-based modeling for shelter demand and decision-support tools for resource allocation. These models assess how flooding and transportation disruptions affect access to critical facilities. Traditional approaches fail when multiple threats occur simultaneously, and limited data complicates planning. USACE's solution improves evacuation efficiency, resource allocation, and infrastructure repair strategies, providing emergency managers with better tools for disaster response.

Cloud-Enabled Numerical Model Modernization

Why it matters: Faster, smarter water decisions with modern cloud-based modeling tools.

USACE's Numerical Model Modernization (NMM) initiative aims to improve water resource project design, operation, and decision-making by modernizing complex, outdated models. These models are being transitioned to cloud computing for better support of Flood Risk Management, Navigation, and Aquatic Ecosystem Restoration missions. NMM also collaborates with academia to integrate the technology into curricula and offer STEM internships. The solution restructures models for modularity, integration, and cloud computing, creating more flexible, accessible platforms. The impact will provide timely, cost-effective solutions and improve training and community-based simulations.

Shoreline Evolution Modeling for Coastal Erosion Protection Planning

Why it matters: 17:1 ROI via optimization of sand volume in a typical coastal storm risk management project

USACE's GenCade shoreline model, initially based on longshore transport and beach profile equations, has been enhanced with cross-shore sediment transport and Monte Carlo simulations to address complexities in nearshore processes and inlet dynamics. This improved model supports coastal protection planning, guiding decisions on beach fills, sand bypassing, and coastal structure design. GenCade’s one-dimensional approach, enhanced with Monte Carlo functionality, allows for more precise modeling of coastal processes and accurate erosion risk assessments. Validated through simulations in Duck, NC, and Absecon Island, NJ, GenCade is crucial for USACE coastal engineering studies.

Learn more at: https://cirp.usace.army.mil/techtransfer/discussions/FY24/CIRP_TD_GenCade_CMS_20231128.pdf

Water Resource Infrastructure Digital Twins

Why it matters: Digital twins provide decision support to reduce failure risk of critical infrastructure

Aging U.S. dams, many beyond their life expectancy, face increased failure risks, and rehabilitation is costly and labor-intensive. To address this, a digital twin framework was developed to enable real-time analysis of dam infrastructure, combining failure models, sensor data, and AI/ML techniques to predict risks and guide rehabilitation priorities. The framework integrates structural health monitoring and risk modeling to improve decision-making. Version 1.0 will be deployed at Isabella and Bluestone dams in 2023, with future expansions planned.

Learn more at: https://ascelibrary.org/doi/10.1061/9780784484692.041

Structural Health Monitoring (SHM) Partnerships

Why it matters: SHM research resulted in foundational technologies to inform better infrastructure decisions.

The USACE Structural Health Monitoring (SHM) program uses sensor data, multi-physics models, and statistical analysis to assess critical infrastructure condition. Collaborating with academic and industry partners, the program has advanced digital twin modeling, robotic inspections, non-contact sensing, and data acquisition techniques. With over $250 billion in infrastructure, much of it over 50 years old, accurate data is crucial for smart maintenance decisions. The program’s advancements, resulting in over 30 peer-reviewed publications, will enhance future SHM research and improve infrastructure maintenance.