3D Concrete Printing: The future of retail construction
Three-dimensional concrete printing (3DCP) is shaping up to be a faster, more sustainable building opportunity — and Walmart is already taking advantage.
Unlike traditional concrete which is designed to be mixed and poured into forms directly onsite, 3D-printed concrete is created very differently. Designed through modeling software, reinforcement fibers are loaded into a 3D printer which creates construction materials — layer by layer — to scale.
“The process is similar to traditional mixing, but 3D-printed concrete has the ability to flow easily while staying in place after extrusion,” explained Matt Abeles, VP of construction technology and innovation for trade group Associated Builders and Contractors (ABC). “3D concrete has a thicker, paste-like consistency. This concrete has the strength to hold up under its own weight immediately after extrusion while still being workable enough to be pumped through the printer’s system, making it very flexible.”
Bullish on the innovative concept, Walmart last fall created one of the largest freestanding, 3D-printed commercial concrete structures in the United States. In a pioneering move, the retail giant partnered with 3D concrete printing company Alquist 3D to print a nearly 8,000-sq.-ft., 20-foot-high addition to its store in Athens, Tenn.
The addition, which is dedicated to the store’s online pickup and delivery program, marks the first time Walmart has utilized 3D-printed concrete at this scale. Industry-wide, this is also the first 3D-printed facility of its kind — but likely won’t be the last.
“While its adoption in the retail sector is still in the early stages, 3D printed concrete remains a topic of interest and exploration across the industry,” said Julie Hyson, Americas portfolio clients, services and industries lead at commercial real estate firm JLL.
“Now that Walmart dipped their toe in the water, the tides could turn quickly,” she added. “Store development professionals want to find solutions that help them do their jobs better. Retail is also a close-knit community and partnering with vendors in this space will help accelerate progress.”
Chain Store Age’s Deena Amato-McCoy spoke with Abeles and Hyson about how 3D printed concrete will impact retail construction projects going forward.
What business benefits does 3DCP offer?
Abeles: The top benefits include reduced costs, less complex construction schedules and less materials waste, making 3DCP a more sustainable option. As adoption rates increase, retailers will also quickly recognize how this concrete can be more easily applied to complex geometries and shapes (such as undercuts, hollow spaces or intricate internal structures), enabling them to more efficiently complete projects at lower costs.
Can you elaborate on 3DCP’s sustainable opportunities?
Hyson: This material will not only advance construction capabilities, it will also be a key component helping retailers meet their net zero deadlines. Innovative companies are exploring all ideas as a means to achieve their sustainability goals. Besides reducing building material usage, 3DCP creates less materials waste. Shorter print time also saves energy.
How will early adopters gain a competitive advantage?
Abeles: Speed to market is a very competitive advantage when it comes to new builds. Any opportunities that can potentially reduce build time should be a viable option for retailers.
However, there are factors to consider when evaluating 3DCP for projects. For example, construction stakeholders should look for ease of availability and access to equipment, as well as advances in equipment and materials technology. Return on investment is also important so projects should ensure they can lower costs — and retailers should be ready to re-invest these budgets into workforce upskilling.
Hyson: Upskilling will be a very important factor impacting the overall adoption of 3DCP. A construction project requires the expertise of architects, general contractors, mechanical engineers, and project managers, among other professionals, across retailers and property developers. The industry is still learning how to migrate toward 3D concrete and how processes will change. That means everyone must be trained and educated on the materials, how the concrete should be integrated within projects, what inspections should look like going forward, and how to scale projects. It will be a work in progress.
What is the future of 3D printed concrete?
Abeles: Since the process is still evolving, stakeholders are still learning. As they educate themselves, retailers should be mindful of 3DPC’s compliance with local building codes, as well as how seamless integration is between 3DCP and traditional building methods. They should also be considering what needs to go into quality control and certifications, as well as overall costs of equipment and design standards for 3D-printed structures.
Hyson: Clearly, there is a lot of excitement around the concept, but educate is important. We also advise clients to start small. Projects should be scaled slowly to gain experience, and clients should not be afraid to learn from projects that don’t go as planned.
It is also important to pick experienced partners. They can help retailers evaluate how to integrate materials into existing operations, and teach them what 3D-printed concrete requires from a maintenance perspective. This process doesn’t have decades of data to refer to, so there will be an ongoing learning curve for all involved.