Walmart Has 3D Printed Groundbreaking Concrete Expansion

As online shopping interfaces become increasingly popular, new solutions to support this technology must be developed. That’s why Walmart built an extension to their store in Athens, Tennessee that’s dedicated to online delivery and pickup services. However, this building is more than just a delivery center. Standing at over 20 feet high and measuring nearly 8,000 square feet, it is one of the largest free-standing, 3D printed commercial concrete structures in the United States. 

Walmart explored several innovative construction technologies for the expansion project but decided to pursue 3D printing concrete because it allows for accelerated construction and aligns with their broader sustainability goals. They hired Alquist 3D for the job, and Mike Neill, VP of New Construction for Walmart, said it was because “Alquist presented the best ability to work with due to their deep knowledge of 3D materials, robotics, and desire to take on an ambitious and unique project.” Alquist 3D was also an ideal fit because of its connections with industry leaders like SICA and RIC Technology. 

A worker monitors the 3DCP process

3D concrete printing, or 3DCP, is a form of material extrusion that pushes concrete through a nozzle attached to a robotic arm. This type of additive manufacturing is advantageous for architecture because it requires less labor, can handle complex designs, and uses carbon-neutral materials. 3DCP has already been widely employed in architecture, but this Walmart building will be unique because it is the largest 3D concrete printed retail building in the US. Zachary Mannheimer, Founder and Chairman of Alquist 3D, said “It is the first such facility of its kind and it’s just incredible that it is a reality. This is going to play a major role in the advancement of 3DCP technology.”

While working on the project, Alquist reported that their team learned the importance of managing material temperatures. In the hot Tennessee summer weather, the builders had to use water to regulate the concrete temperature to make it ideal for printing according to media. Additionally, it was noted that there were issues with Alquist’s original pump getting clogged, which delayed the project for several weeks. By working through these difficulties, Alquist learned how to achieve faster print times, and successfully built a 20-foot wall for the first time. Given their achievement with this build in Athens, Alquist will work on a second project with Walmart soon. Watch this video to see 3DCP in action and read here to learn more.

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*All photo credits Dustin Chambers for Wall Street Journal