New Concrete Press Capabilities Unveiled, Exploring Its Potential and Limitations in Various Applications
In an exciting development for the construction industry, a groundbreaking project in Metzingen, Germany, is pushing the boundaries of Additive Manufacturing and Concrete Construction. This pioneering initiative, led by Züblin and Instatiq, is making strides in 3D printing structural load-bearing walls for regular residential construction directly on-site [1][2][3].
The Metzingen project, as reported by Dominik Hochwarth, an editor at VDI Verlag, aims to create a scalable process suitable for various building types, locations, and requirements, focusing on industrial application rather than a mere gimmick [1]. The project involves the construction of 44 residential units across three apartment blocks, serving as a real-world testbed for integrating 3D concrete printing as a viable, sustainable, and efficient alternative to traditional construction methods at scale [3][5].
One of the key benefits of this 3D printing process is efficiency. The printing progresses at about 10 cm per second, enabling the completion of load-bearing walls significantly faster than traditional masonry—reducing construction time by half for the top floor and requiring far fewer workers [1]. Precision digital instructions minimize rework and eliminate errors from misinterpretation of blueprints [1].
Sustainability is another significant advantage of this method. It uses off-the-shelf concrete from local plants, avoiding specialized prefabricated parts and the emissions associated with shipping these. The resource-saving approach optimizes material use and construction workflow [2][4][5].
Addressing the skilled labor shortage is another key benefit. The automation of the printing process substitutes for traditional labor-intensive masonry work. The robotic printer does not require breaks and lowers the need for highly skilled masons on site, easing the current skilled labor scarcity in construction [1].
The entire 3D printing process can be realized electrically, making it an advantage if electricity from renewable sources is available. In the long term, recycled materials are planned to be used in the 3D printing process, reducing the ecological footprint and saving costs [6].
Züblin and Instatiq are planning to bundle their cooperation in a joint venture named Nelcon, offering services around 3D concrete printing (subject to antitrust approval) [7]. With the printing system, a floor can be realized with fewer workers, offering better working conditions with less dust, less noise, and more predictable workflows [8]. Chris Brandstätter, a representative, states that the employees benefit from better working conditions with less dust and noise, particularly on large construction sites [8].
This innovation marks one of the first large-scale uses of this technology for load-bearing concrete residential structures in Germany and globally [1][3]. The 3D printing process used by Züblin and Instatiq saves time and reduces CO2 emissions by approximately 20% compared to conventional masonry [9]. As the Metzingen project continues, it promises to reshape the future of residential construction, offering a more sustainable, efficient, and worker-friendly alternative to traditional methods.
Energy-efficient homes are a key outcome of the Metzingen project, given the electrical nature of the 3D printing process and plans to use renewable energy sources.
The integration of technology in construction, through 3D printing gadgets, is revolutionizing the industry, making residential buildings more scalable, sustainable, and worker-friendly.
