Engineers from the German University of Technology Oman (GUtech) worked with construction specialists COBOD and CEMEX to build what they say is the largest building ever to be 3D printed from “real concrete”.

Erected in the Omani capital of Muscat, the 2,100 square foot home, featuring three bedrooms, three bathrooms, living room, kitchen and reception area, was built with a unique additive approach. Developed first by CEMEX and COBOD, and then used to build Angola’s first 3D printed house, the process involves mixing the D.fab solution with local aggregates, in a way that would make filing much easier.

“This revolutionary 3D printing system is a testament to our customer-centric mindset and relentless focus on continuous innovation and improvement,” said Juan Romero, CEMEX Executive Vice President for Development. sustainable, commercial and operational. “By working with COBOD, we have developed a customer experience that is superior to anything that has been provided in the past. “

Innovation activated by adjuvants

To build their home in Oman, the GUtech team turned to COBOD and its BOD2 3D printer, a gantry-mounted system that allows for layer-by-layer construction of multi-story concrete structures. While impressive, the technology itself has been around for quite some time now, and since erecting its first 3D printed building in 2017, COBOD has used it to address construction challenges around the world.

Just last year, the company worked with 14Trees, a joint venture between building materials specialist LafargeHolcim and the CDC Group, to help tackle Malawi’s classroom shortage by 3D printing a school. whole there, and deployed its technologies to build three new low-cost homes, in an effort to tackle the affordable housing crisis in the United States.

Towards the end of 2021, however, COBOD revealed that it had worked with building materials developer CEMEX to find a new method of turning ordinary concrete into a 3D printable material at a lower cost. Essentially, companies have been able to accomplish this by adding CEMEX’s D.fab solution to locally sourced aggregates in a way that makes them more fluid, malleable, and easier to print.

During the first proof-of-concept project to use the material in Angola last year, the companies worked with local contractor Power2Build, who found that the ability to deploy local aggregates enabled them to significantly reduce their construction costs. housing construction, up to less than $ 1,000. for every 575 sq. ft. of house built.

Now, following the success of the second such project of using his machinery and new cement mix in Oman, COBOD founder Henrik Lund-Nielsen says the increased cost-cutting potential of his technologies could allow their application even wider.

“While we were happy to help various cement and concrete manufacturers develop 3D printable dry mortars, we also insisted that a solution for making real concrete from locally available materials would be. necessary for the mass application of our technology, ”Lund-Nielsen added. . “We are more than delighted that CEMEX has taken up the challenge and proud to have been able, in cooperation, to develop the new solution. “

“With the low cost of printed materials, in addition to the savings resulting from the lack of formwork and the minimal team required to run our printers, our disruptive technology is now more competitive than ever. “

Economical Omani 3D printing

Built in just five days, the GUtech team’s unique social housing construction was only made possible through their close collaboration with colleagues from COBOD and CEMEX. Before starting, for example, the Omani team took a crash course in BOD 3D printing, while CEMEX helped formulate the ideal building material for the project.

Once prepared, the engineers found they were able to erect the building quickly, at a reported cost of less than € 1,600. In large part, the team was able to achieve this by sourcing more than 99.5% of the building materials locally, with the remaining 0.5% or so coming from CEMEX additives, and according to COBOD, had the house been made. of dry mortar, it would have cost more than 20,000 €.

After the house was completed on December 14, 2021, it was presented to a crowd of 200 dignitaries, including His Excellency Sultan Al-Habsi, Minister of Finance of Oman. In the future, it is hoped that the project will promote the adoption of 3D printing in the country’s construction industry, as part of its Vision 2040 plans to develop its national technical and entrepreneurial capacities.

“Today’s presentation of the first 3D printed building is perhaps the first stop on the 1,000 mile journey. A step that will not succeed without the support of all parties involved ”, declared Dr Hussain Al Sami, interim rector of GUtech, at the inauguration of the building. “In this regard, I sincerely thank all local and international parties who contribute to the support of the center and the university.

“We hope this center will play its role in supporting Oman’s efforts to achieve Oman’s Vision 2040. “

AM in construction in the Middle East

While COBOD was keen to highlight how the Omani house of GUtech is the first of its kind to be 3D printed from real concrete instead of traditional dry mortars, it is far from the first structure made with additives in the Middle -East. In fact, the region has become a hive of 3D printing activity in recent years, so much so that last year the Prime Minister of the UAE issued an AM building decree.

Around the same time, the government of Dubai unveiled what would be the world’s first 3D printed research lab. Built to serve as an international additive manufacturing center in the emirate’s 77 km² solar park, the Dubai Electricity and Water Authority (DEWA) facility now houses the agency’s rover and drone R&D.

Elsewhere in Dubai, it was revealed last August that property developer Pantheon Development was weighing the 3D print of an eleven-story building. While the company has reportedly discussed the viability of such a structure with three different construction companies, it is not yet clear whether it will pursue its plans.

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The image shown shows GUtech’s Omani house and COBOD’s BOD 2 3D printer during the building’s official inauguration. Image via COBOD.