A Q&A with ORNL’s Samantha Sabatino on how advanced nuclear reactor designs will inform less expensive building techniques
Researchers are designing the next generation of nuclear reactors to be safer, stronger and more secure at a lower cost.
At the Department of Energy’s Oak Ridge National Laboratory, Samantha Sabatino of the Nuclear Construction and Operations Group is helping drive the innovations that make this possible.
Sabatino applies her expertise in structural engineering and risk and reliability analysis to advance a broad range of nuclear systems. Her work plays a critical role in addressing one of the industry’s biggest challenges: how to build reactors more affordably without compromising safety or performance.
Q: What are the biggest costs when building a nuclear reactor today?
A: The largest costs in building a nuclear reactor come from construction, as well as the need to meet stringent safety and security standards. A major expense is the use of specialized materials like high-strength concrete designed to endure extreme events such as earthquakes, fires or high-pressure scenarios. Reactors also must comply with Security and Safety by Design (2-S principles), which integrate features to safeguard against potential accidents and adversarial threats, including sabotage or the theft of nuclear materials.
These requirements often make construction labor-intensive, require advanced technologies, and lead to prolonged timelines, which collectively drive up costs.
Q: What role does construction technology, like 3D printing, play in reducing costs?
A: Modern construction and advanced manufacturing technologies, such as 3D printing, are transforming how reactors are built by streamlining production, reducing waste, and improving the precision of components. 3D printing allows for the creation of complex reactor parts that are lighter and stronger while minimizing material costs and construction errors. When paired with innovative materials like Ultra-High-Performance Concrete (UHPC), which offers exceptional strength, durability and resistance to damage, these technologies enable faster, more efficient construction.
In addition, modular construction techniques, where large reactor components are fabricated in a controlled factory environment and then transported to the site for assembly, reduce on-site labor requirements, and construction timelines.
Q: What scientific challenges prevent us from leveraging new technology for construction?
A: While promising, new materials and construction methods face significant hurdles before they can be widely adopted. For instance, UHPC must meet rigorous testing to demonstrate that it can maintain its structural integrity over the decades-long lifespan of a reactor. It must also prove its resilience to harsh operating conditions, including exposure to high temperatures, radiation, and the potential impact of natural disasters.
3D printing faces a similar challenge, as builds must achieve a high degree of consistency and reliability while complying with strict regulatory standards developed around traditional materials and methods. Existing frameworks must adapt to accommodate these innovative approaches while maintaining safety and security, ensuring that new nuclear systems can built to meet rising energy demands.
Q: How does your research help support efficient nuclear reactor construction?
A: Our research focuses on developing and applying advanced materials and construction techniques that align with 2-S principles. For example, we are testing UHPC to explore its use in reactor structures, given its ability to withstand earthquakes, fires, and physical impacts while maintaining long-term durability.
We are also working to streamline reactor construction through modular designs and advanced manufacturing techniques like 3D printing. These efforts aim to reduce construction timelines, improve structural integrity, and lower costs, all while ensuring that reactors are safe, secure, and reliable throughout their lifetimes.
Q: How might building reactors more affordably and efficiently influence the future of nuclear energy?
A: Building more affordable and efficient reactors can make nuclear energy a more feasible option for countries developing new nuclear programs. Cost reductions stemming from more affordable construction can allow for quicker projects with lower financial risk, encouraging support from both investors and decision-makers.
Efficient construction also supports long-term sustainability by ensuring the reactors are reliable, durable, and easy to maintain. By incorporating innovative materials such as UHPC and modular designs, which reduce risks and enhance resilience, these reactors will not only meet energy demands but also provide a stable and secure option for energy production with minimum disruptions over their operational lifetimes.
This research is funded by the U.S Department of Energy’s Light Water Reactor Sustainability Program.
UT-Battelle manages ORNL for DOE’s Office of Science, the single largest supporter of basic research in the physical sciences in the United States. The Office of Science is working to address some of the most pressing challenges of our time. For more information, please visit energy.gov/science.
