3D concrete printing: versatile technology that stands

In 2017, Saint-Gobain Weber Beamix, together with BAM Infra, Eindhoven University of Technology (TU/e) and others, created a downright world first: the first fully 3D printed construction, namely a bicycle bridge in Gemert. The technology used at the time has since grown into a fully-fledged and versatile production method for a variety of objects in which freedom of form and CO2 reduction are key. From bridges, lost formwork and outdoor furniture to inspection and sewer manholes, skate parks and talus stairs. It is precisely this last product that firmly symbolizes the competencies that Weber Beamix has in terms of 3D concrete printing anno 2024. "The technology is mature," says project manager Pieter Bakker. "Our talus stairs are the ultimate confirmation of that." 

3D printing with concrete mortar. Saint-Gobain Weber Beamix has been experimenting with it for more than two decades. It produced the first 3D printed wall in 2005. The development in the field of 3D concrete printing really accelerated some 10 years later, thanks to the 3DCP project of the TU/e. Within a consortium of companies, this experiment gradually grew into a new production method in construction. The result? The opening of the first concrete printing plant in Europe in 2019 and several high-profile projects. Saint-Gobain Weber Beamix has fully owned this production facility, located in Eindhoven, since May 2021. Here, a professional project team is engaged daily in producing first-class concrete creations, discovering the many possibilities of 3D concrete printing and its further rollout. From the creation of the fledgling design to the final installation on site.

Full 

In conversation with Pieter, the advantages of 3D concrete printing technology soon surface. "3D concrete printing stands for speed and unprecedented freedom of form. But first and foremost, you make a very sustainable choice with this method. After all, concrete is used only where it is actually needed. Take our talus stairs for example, of which we have already made dozens. Because you print hollow steps and the printer only places concrete where it is needed for structural strength, the 3D production technique can save up to 50% in materials. In addition, no reinforcing steel is used. Together, this results in CO2 savings of as much as 40 to 60%." 

Started early, won a lot

3D concrete printing offers plenty of opportunities. To take advantage of its full potential, however, Pieter believes it is important to think from the perspective of printing technology already during the design of elements and objects. "Topological design, for example, is a discipline that lends itself perfectly to 3D printing technology," he believes. "Simply because the computer calculates the most optimal design to reduce weight and material. In that respect, the infrastructure sector can take a cue from the aircraft industry, a sector where topological design and 3D printing have long gone hand-in-hand. That combo can produce wonderful results in the construction industry as well."

For all

These are pluses that have propelled the production process into a mature technology that stands. 3D concrete printing in 2024 has become a serious alternative for realizing a wide variety of building products. "The technology as it stands today allows us to print any talus staircase we want. Regardless of size or shape. And at a competitive cost. In addition, designing them can be quick and easy. To this end, we offer a special configurator on our website. A beautiful and process-simplifying tool that allows anyone to design their own customized talus staircase in a matter of minutes. We then ensure that the desired end product is delivered within three weeks."

On the map

It is clear: Saint-Gobain Weber Beamix's 3D printed objects are conquering an increasingly firm place on the map. Literally even. At www.3D.weber all 3D concrete printing projects realized by the company in the Netherlands and abroad can be admired on a convenient map, including, of course, the talus stairs. Solid examples of the knowledge and skill of the project team that should be the prelude to many more beautiful things towards the future. "We delivered one of the last talus staircases made by us as part of the project Verbreding A1 Apeldoorn-Twello, a tightly executed work that Heijmans is carrying out on behalf of the Directorate-General for Public Works and Water Management and within which sustainability and innovation are high on the agenda," Pieter explains. "In close cooperation with Jenniskens Kraanverhuur, we recently installed a very beautiful 3D printed concrete talus staircase for this purpose. An object that fits perfectly into the landscape and fits perfectly with the formulated project objectives." That opinion is also shared by Willian Nijenhuis, project manager on behalf of Heijmans Infra CP Realisatie. "The smooth cooperation has resulted in a beautiful, robust and sustainable end result. The delivery of the cross section from the design was sufficient to realize the talus stairs. After this, Saint-Gobain Weber Beamix took over the process until realization. This form of unburdening is a great advantage. In addition, the prefabricated realization of talus stairs reduces the workload of the professionals in the field. A welcome extra, since the availability of craftsmanship is becoming an increasing problem."