Walmart opens 3D concrete-printed addition at Alabama supercenter
Walmart Inc. is following up on an historic construction milestone it achieved in fall 2024.
The discount giant partnered with 3D concrete printing company Alquist 3D and general contractor FMGI Inc. to complete construction of its second freestanding, 3D concrete-printed store addition. Robots and 3D concrete printing by Alquist 3D built the 16-foot walls of the 5,000-sq.-ft. expansion of the Walmart supercenter in Owens Cross Roads, Ala. The addition, which was completed 50% faster than normal construction methods, serves as the retailer’s online grocery pick-up and delivery location and is part of an overall store remodel.
Walmart initially teamed with Alquist 3D in fall 2024 in what was a first-of-its kind construction project to print a nearly 8,000-sq.-ft., 20-foot-high addition to its store in Athens, Tenn. to enhance its online pickup and delivery program. The project marked first time Walmart utilized 3D concrete-printing technology at this scale and was also the first 3D-printed facility of its kind.
[READ MORE: Walmart makes history with 3D-printed store addition]
“These tests aim to evaluate alternative techniques to traditional construction, while maximizing sustainability,” said LB Johnson, VP of construction at Walmart. “Our approach to innovation is designed to optimize processes and simplify field operations – leading to reductions in project costs and timelines. This will enable speed to market for our customers and help accelerate evolution in the construction industry.”
The walls of the new addition in Alabama were completed in one week — significantly faster than traditional building methods — and addressed two of the construction industry’s biggest challenges: “takes too long” and “costs too much," Alquist 3D noted in a release. The company's robotic arm layered concrete to build the walls cheaper and three times stronger than normal construction methods, Alquist said.
"In a commercial construction world that pays so much attention to project timelines and costs, our work with Walmart shows that 3D printing isn’t just a novelty — it’s an innovation ready to scale for retail and other industries," said Patrick Callahan, CEO of Alquist 3D. “This second project clearly demonstrates how retail expansions can be faster, more cost-effective and less wasteful, paving the way for broader adoption for large-scale commercial builds."
FMGI, the general contractor on the site, provided on-site coordination, ensuring the advanced 3D printing process worked seamlessly with conventional construction tasks.
“We’re proving that 3DCP is cheaper and greener than standard CMU construction,” said Darin Ross, president and CEO of FMGI. “This build cost 15% less and produced 55% less waste than the first 3DCP build late last year in Athens, Tenn.”
Other companies working on the Alabama addition included Sika USA, which supplied customized concrete mixes formulated to address varying environmental conditions. In addition, Alquist’s robotics partner RJC Technology, which furnished robotic systems designed to achieve high-precision printing with reduced labor requirements.
Walmart pilots 3D weaving technology for apparel
The retailer’s foray into 3D printing of construction materials follows a pilot it began in March 2024 of first-of-its-kind 3D weaving technology from Unspun in its apparel supply chain for private label men’s chinos. Unspun’s proprietary solution uses 3D capabilities to eliminate the steps of cutting and stitching fabric from apparel creation, going straight from yarn to garment.
As a result, fabric loss, discarded inventory and transport emissions are removed from the apparel supply chain, while production can be sourced locally and on demand.
Headquartered in Bentonville, Ark., Walmart Inc. operates more than 10,500 stores and numerous e-commerce websites in 19 countries.
