3D Concrete Printing: Building a Quicker Future for Aussie Construction?

3D printing in construction, while still considered by some to be a novelty, is gaining traction as a potentially faster and, in some cases, more sustainable alternative to traditional Australian building methods. As companies globally race to refine designs and slash printing times, the question arises: can this technology truly reshape the future of construction Down Under?

Global Advancements in 3D Printing Construction

The original article highlighted Icon, a Texas-based construction tech company, showcasing their ability to print a concrete house in under 24 hours for under $US10,000. Icon has partnered with New Story to deploy their printer in El Salvador to build around 100 homes for people living in slums.

Richard Sansom, a Project Manager at JLL, notes, “3D printing has taken huge steps forward in recent years and companies are really pushing the boundaries of what’s possible. A key driver for recent developments has been the shortage of housing in numerous cities across the world.”

The process involves large-scale printers layering materials, primarily cement, according to a digital blueprint. Additives can accelerate hardening, potentially reducing construction times from months to days and cutting waste by up to 30 percent. 3D printing has the potential to reduce waste material by up to 30 percent. (Source: “A review of concrete 3D printing technology” by Khoshnevis et al., *Automation in Construction*, 81 (2017): 1-13.)

While on-site printing is possible, component-based construction, where printed elements are manufactured offsite and then assembled, is often preferred. Expanding beyond concrete, companies like a Canadian firm, have developed 3D printers for steel studs and panels, significantly reducing frame assembly times.

Implications for the Australian Construction Industry

The Australian construction industry, currently grappling with skills shortages, rising materials costs, and project delays, is ripe for technological disruption. 3D printing offers potential solutions, but also poses unique challenges.

Potential Benefits

• Reduced Labour Costs: Automation through 3D printing could alleviate the strain of skilled labour shortages, common in areas like bricklaying and formwork, and allow for potentially more women or more people from diverse backgrounds to enter the workforce.
• Faster Project Delivery: Accelerated construction timelines mean quicker returns on investment for developers and faster availability of housing or infrastructure.
• Cost Reduction: While the initial investment in 3D printing technology can be substantial, reduced labour and material waste could lead to long-term cost savings, particularly in large-scale projects.
• Improved Sustainability: Minimising material waste and potentially utilising locally sourced materials aligns with growing demands for sustainable building practices.

Challenges and Considerations

• Regulatory Hurdles: Australia’s building codes and standards haven’t yet caught up with 3D printing. Gaining regulatory approval for 3D-printed structures will require rigorous testing and certification processes.
• Skills Gap: While reducing reliance on some traditional trades, 3D printing creates a demand for new skillsets in areas like printer operation, software modelling, and materials science. Upskilling and training initiatives are crucial.
• Material limitations: There are a finite number of materials approved in Australia for building purposes, and current materials used in 3D printing may not meet expectations. Further testing and research is required.
• Public Perception: Overcoming skepticism and gaining public trust in the safety and durability of 3D-printed buildings will be essential for widespread adoption.

Applications in the Australian Context

According to the original article, 3D-printing offers a faster, more cost-effective way to construct buildings, it could be first adopted for civic housing initiatives. A 1000-square-foot home in Nantes, France was printed in 54 hours as a model for social housing, while the world’s first 3D printed housing complex is set to be completed next year in the Dutch city of Eindhoven.

“3D printing could have the most immediate impact in real estate sectors where the structures are homogenous, and economies of scale can be realised, such as in student accommodation, hotels, and affordable housing,” Sansom says.

Like most countries in the world, 3D printing lends itself to sectors with homogenous requirements. The application of 3D printing in Australia is broad. 3D printing could initially find a niche in:

• Affordable Housing: Addressing housing affordability is a key political and social issue. 3D printing could offer a viable solution for rapidly constructing low-cost, high-quality homes.
• Remote Communities: Transporting materials to remote areas of Australia is expensive and logistically challenging. 3D printing using locally sourced materials could revolutionise construction in these regions.
• Disaster Relief: As mentioned in the original article, portable 3D printers could be deployed to disaster zones to quickly build emergency shelters using readily available resources.
• Mining and Resources Sector: 3D printed Mining camps and facilities could be built to lower materials costs for remote workers.

BIM and the Digital Construction Ecosystem

The original article mentioned building information modelling (BIM) systems, an important part of adopting 3D printing for construction. The integration of BIM with 3D printing is crucial. BIM provides the digital blueprint for the printer, ensuring accuracy and coordination. While BIM adoption in Australia is growing, it is not yet as widespread as in places like Dubai, according to the original article. Encouraging wider BIM adoption will pave the way for seamless integration of 3D printing technologies.

The Path Forward

While 3D printing in construction holds immense promise for the Australian market, several steps are needed to unlock its full potential:

• Government Support: Investment in research and development, skills training, and regulatory framework development is essential.
• Industry Collaboration: Collaboration between construction companies, technology providers, and research institutions is crucial to drive innovation and adoption.
• Pilot Projects: Undertaking pilot projects across diverse applications will showcase the benefits of 3D printing and build confidence in the technology.

Conclusion

The Australian construction industry stands at a crossroads. Embracing 3D printing requires a proactive approach, addressing regulatory hurdles, investing in skills development, and fostering collaboration. While mass adoption may still be some time away, the potential benefits for affordability, sustainability, and efficiency are too significant to ignore. As the technology develops, and as the price point becomes competitive, the Australian construction landscape may well be altered.

Source: Adapted from “3D printed buildings push construction boundaries,” JLL, accessed November 24, 2023, https://www.jll.com.mo/en/trends-and-insights/investor/3d-printed-buildings-push-construction-boundaries.

This article is based on a report from www.jll.com.mo titled “3D printed buildings push construction boundaries”. You can find the original article here: https://www.jll.com.mo/en/trends-and-insights/investor/3d-printed-buildings-push-construction-boundaries