Innovative Techniques in Military Construction

Defense Posture and Global ThreatsHouse Appropriations Subcommittee on Military Construction, Veterans Affairs, and Related Agencies · March 11, 2025 · 119th Congress
The House Appropriations Subcommittee on Military Construction, Veterans Affairs, and Related Agencies held this hearing to examine how innovative technologies — including 3D printing/additive construction, mass timber, industrialized/modular construction, and alternative power generation — could reduce military construction costs and timelines. Begins at ▶ 0:04:51
Transcript
Highlights

Title

Reducing military construction costs through innovative building technologies

Purpose

The House Appropriations Subcommittee on Military Construction, Veterans Affairs, and Related Agencies held this hearing to examine how innovative technologies — including 3D printing/additive construction, mass timber, industrialized/modular construction, and alternative power generation — could reduce military construction costs and timelines. Witnesses from the Army Corps of Engineers, Naval Facilities Engineering Systems Command, Hyliion, and CNA testified on current pilot projects, technical barriers, and statutory changes that could accelerate adoption. Ranking Member Wasserman Schultz also used the hearing to raise concerns about administration cuts to VA staffing and tariff impacts on construction costs. Begins at▶ 0:04:51

Who spoke

• Chairman John Carter (R-TX)▶ 0:04:51: Opened by welcoming new members Rep. Alford and Rep. LaLota, and noted a study finding military construction can cost up to 35% more than comparable private-sector projects▶ 0:06:22; later asked witnesses whether 3D-printed structures are reliable in hot and cold climates▶ 0:33:44 and about Indo-Pacific construction challenges▶ 0:38:47.

• Ranking Member Debbie Wasserman Schultz (D-FL)▶ 0:08:23: Criticized administration plans to cut 880,000 VA jobs and cancel nearly 600 contracts▶ 0:09:23, cited a fired disabled veteran named Ben as an example▶ 0:10:24, and warned that new tariffs on steel and aluminum will raise costs and drive more reprogramming requests▶ 0:43:20; pressed Mr. Morrow on whether tariff impacts were being seriously assessed▶ 0:45:51.

• Mr. Dave Morrow, USACE Director of Military Programs▶ 0:13:56: Described USACE's reliance on Unified Facilities Criteria to enable innovative designs▶ 0:14:57 and additive construction now allowed in 80% of the U.S.▶ 0:16:28; discussed a mass timber barracks pilot at Joint Base Lewis-McChord▶ 1:01:05 and confirmed AFFF firefighting foam system replacement contracts total about $56 million▶ 1:04:06.

• Mr. Keith Hamilton, NAVFAC Chief Engineer▶ 0:19:01: Explained NAVFAC's acceleration and affordability campaign and use of Other Transaction Authority (10 USC 4022) to pilot an industrialized Child Development Center in Little Creek, VA▶ 0:21:32; noted cross-laminated timber use in Hampton Roads and high-performance concrete at Cherry Point▶ 0:22:02, and said statutory/regulatory flexibility is needed to expand alternative delivery methods like progressive design-build▶ 0:23:33.

• Mr. Thomas Healy, CEO, Hyliion▶ 0:24:03: Introduced the Karno modular power generator, a 3D-printed, fuel-flexible system with up to 50% efficiency versus the grid's 36%▶ 0:27:05; said the first unit was delivered to the Navy for testing▶ 0:26:04, and confirmed the generator is not currently EMP-hardened▶ 0:56:29.

• Mr. Brent Richardson, CNA Principal Research Scientist▶ 0:30:10: Presented CNA's study on barriers to innovative milcon techniques, recommending a DOD technology roadmap▶ 0:30:40 and earlier contractor involvement in design▶ 0:31:41.

• Rep. Michael Cloud / Rep. (Texas member referenced as "Congressman") — not independently identifiable by name in transcript; questions on seismic/heat performance attributed to Chairman Carter above.

• Rep. Julie Fedorchak / unnamed Republican member ("Congressman Rutherford")▶ 0:52:58: Asked Mr. Hamilton about multi-year O&M appropriations easing supply-chain issues, citing cross-laminated timber work at Joint Base Lewis-McChord▶ 0:53:58; asked Mr. Healy about EMP protection▶ 0:56:29 and Mr. Morrow about using O&M funds for beach erosion repairs at Blount Island Command▶ 0:57:30.

• Rep. (Georgia member, "Mr. Bishop")▶ 0:59:33: Discussed Georgia's timberland industry and mass timber policy, asked about a possible four-year continuing resolution's effect on FY29 Georgia milcon projects▶ 1:02:35, and asked about PFAS/AFFF phase-out progress▶ 1:03:05.

• Rep. (Oklahoma member, referencing Tinker AFB)▶ 1:06:07: Highlighted augmented reality use at Tinker's Bomber Agile Hangar▶ 1:06:07 and asked Healy and Richardson about barriers startups face entering DOD contracting▶ 1:07:08; asked Morrow and Hamilton whether green/environmental mandates drive up milcon costs▶ 1:08:38.

• Rep. (representing Fort Bliss, "Mrs. Bice" area)▶ 1:12:40: Praised Fort Bliss's 3D-printed barracks▶ 1:13:11, cited data showing El Paso military housing costing up to 500 times more than comparable local university housing▶ 1:14:41, and asked Morrow what latitude installation commanders need to expand 3D printing▶ 1:15:42.

• Rep. (energy and water subcommittee member)▶ 1:18:18: Asked Hamilton and Morrow about statutory barriers to early contractor involvement▶ 1:18:48 and Richardson about the proposed milcon technology roadmap▶ 1:19:48; questioned Healy on Karno generator ROI and government contracting's ability to weigh long-term value▶ 1:21:19.

• Rep. (Camp Pendleton member)▶ 1:23:19: Described touring Camp Pendleton barracks in poor condition, with about half of 125 buildings needing rehabilitation or teardown▶ 1:23:50; asked about testing larger, multi-story 3D-printed and mass timber facilities under seismic constraints▶ 1:24:50, and industrialized construction for the Barracks 2030 initiative▶ 1:27:52.

• Rep. (Navy veteran, Western Pacific deployments)▶ 1:29:25: Described visiting dilapidated Indo-Pacific bases 20 years after deployment▶ 1:29:55 and asked Hamilton how the Navy can be more agile in adopting construction technologies in the Indo-Pacific▶ 1:30:25; also questioned Richardson and Morrow on reducing bureaucratic barriers▶ 1:32:26.

• Rep. Michael Guest (R-MS)▶ 1:33:56: Asked about ERDC's mission and resourcing, referencing a visit to the Vicksburg facility▶ 1:34:27, and asked Hamilton about applying innovations to renovating aging hangar facilities at Naval Air Station Meridian, including hangar 2's roof▶ 1:37:28.

Key moments

• Chairman Carter cited a study finding military construction costs run as much as 35% more than comparable civilian construction▶ 0:06:22.

• Wasserman Schultz said the administration plans to cut 880,000 VA jobs and cancel nearly 600 contracts, and cited a fired disabled veteran, Ben, as an example of the impact▶ 0:09:23▶ 0:10:24.

• Sharp exchange: Wasserman Schultz pressed Morrow on whether a 50% tariff on steel and aluminum would raise milcon costs; Morrow repeatedly said "it's too early to tell," prompting her to say the cost-estimating system "isn't working"▶ 0:45:51▶ 0:46:22.

• Healy said the Karno generator reaches up to 50% efficiency versus the standard grid's roughly 36%, and operates on more than 20 fuel types including diesel, natural gas, propane, and JP8▶ 0:26:35▶ 0:27:36.

• Hamilton disclosed NAVFAC is piloting an industrialized Child Development Center in Little Creek, VA under Other Transaction Authority (10 USC 4022), aiming to scale the approach across the Mid-Atlantic and Southwest▶ 0:21:32.

• Morrow confirmed the final AFFF firefighting-foam system replacement contracts, estimated at about $56 million, are ready for award but not yet funded▶ 1:04:06.

• A member representing El Paso/Fort Bliss cited local data showing military barracks construction costing 68% to 500% more than comparable local university housing▶ 1:14:41.

• Morrow and colleagues testified that 3D-printed concrete construction is currently limited to single-story buildings in low seismic zones, though a new single-arm printer capable of reaching 27 feet (roughly two stories) is in testing▶ 1:26:21▶ 1:27:21.

• A Camp Pendleton-area member said roughly half of the base's 125 barracks buildings need to be torn down or rehabilitated, with the "Barracks 2030" initiative requiring completion by 2043 and estimated costs exceeding a billion dollars▶ 1:23:50▶ 1:27:52.

• Hamilton and Morrow agreed that additional flexibility to bring construction contractors in early ("early contractor involvement") requires statutory or regulatory change, since current rules make it difficult under standard design-bid-build contracts▶ 1:12:10▶ 1:19:48.

Metadata

CommitteeHouse Appropriations Subcommittee on Military Construction, Veterans Affairs, and Related Agencies
Chamber / CongressHouse · 119th Congress
DateMarch 11, 2025
TypeHearing
Witnesses
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
Videoyoutube
Transcript196 caption blocks · 14,931 words · 1:43:25 runtime
EventCongress.gov 118007