Frequently Asked Questions

Features:

• Layer-by-Layer Construction: Similar to other 3D printing processes, 3D concrete printing builds structures layer by layer, allowing for intricate and customized designs.
• Material Flexibility: Concrete mixtures can be tailored to meet specific requirements, such as strength, durability, and curing time, depending on the project’s needs.
• Complex Geometries: It enables the construction of complex geometries that would be difficult or impossible to achieve with traditional concrete construction methods.
• Reduced Waste: With precise material deposition, 3D concrete printing can minimize material waste compared to traditional construction methods.
• Rapid Construction: It can significantly speed up the construction process, as it eliminates the need for formwork and reduces manual labor.

Benefits:

• Cost-Effectiveness: By minimizing material waste, labor costs, and construction time, 3D concrete printing can potentially lower overall construction costs.
• Customization: It allows for the creation of customized designs and structures, offering architects and engineers greater design freedom.
• Sustainability: With its potential to reduce material waste and energy consumption during construction, 3D concrete printing has the potential to be more environmentally friendly than traditional construction methods.
• Improved Safety: By reducing the need for manual labor and potentially hazardous construction tasks, 3D concrete printing can enhance safety on construction sites.
• Versatility: 3D concrete printing can be used to construct a wide range of structures, including residential buildings, commercial buildings, infrastructure components, and even artistic installations.
• Remote Construction: In remote or challenging environments, such as disaster-stricken areas or space exploration missions, 3D concrete printing can offer a viable solution for rapid and efficient construction.

Overall, 3D concrete printing holds significant promise for revolutionizing the construction industry by offering faster, more cost-effective, and customizable construction solutions with reduced environmental impact.

The short answer is yes, however the saved time is even more valuable.

The cost comparison between 3D concrete printing and traditional construction techniques can vary depending on several factors, including the project’s scale, complexity, location, and existing infrastructure. Here are some considerations:

• Initial Investment: 3D concrete printing may require a significant initial investment in equipment, software, and training. However, over time, as the technology matures and becomes more widely adopted, these costs may decrease.
• Labor Costs: 3D concrete printing has the potential to reduce labor costs by minimizing the need for manual labor in tasks such as formwork assembly and concrete pouring. However, skilled operators and technicians are still required to operate and maintain the 3D printing equipment.
• Material Costs: The cost of materials for 3D concrete printing can vary depending on the type of concrete mixture used, as well as any additives or reinforcements required. In some cases, specially formulated concrete mixtures may be more expensive than conventional concrete mixes.
• Construction Time: 3D concrete printing has the potential to significantly reduce construction time compared to traditional techniques, as it eliminates the need for formwork and allows for rapid layer-by-layer construction. Faster construction timelines can translate to cost savings, particularly in projects where time is a critical factor.
• Waste Reduction: By minimizing material waste through precise deposition, 3D concrete printing can potentially reduce material costs compared to traditional construction methods, where excess material often goes to waste.
• Design Complexity: 3D concrete printing offers greater design flexibility and the ability to create complex geometries that may be challenging or costly to achieve with traditional construction techniques. This can lead to cost savings in design and engineering, as well as potentially reducing material usage.

Overall, while 3D concrete printing has the potential to reduce costs in certain aspects of construction, such as labor and material waste, its overall cost-effectiveness compared to traditional construction techniques may vary depending on the specific circumstances of each project. However, across the board this technology largely reduces the time it takes to build a home, which we see as the most critical resource for those rebuilding Lahaina.

Consult with us.

For Lahaina rebuilds, printing can begin off site immediately. With the involvement of a competent architect, under state law and with release of any federal restrictions, construction can begin immediately under emergency dispensation. A case by case basis based on availability of water, power, and sewer will most likely be the control. 

Having the walls preprinted and other parts prefabricated ensures incredibly fast construction time. 

3D concrete printing offers several environmental benefits compared to traditional construction methods, making it a promising technology for sustainable construction practices:

• Reduced Material Waste: Traditional construction methods often result in significant material waste due to imprecise cutting, excessive use of formwork, and overordering of materials. 3D concrete printing allows for precise material deposition, minimizing waste and reducing the environmental impact associated with excess material disposal.
  The amount of concrete needed for a 3DCP wall is remarkably less than traditional methods, an interior wall requires a width of 4 cm of solid concrete, while a plumb wall or exterior wall requires (2) 4 cm sections with an air gap. These concrete walls are 8cm of concrete rather than 8 inches.
• Energy Efficiency: 3D concrete printing reduces energy consumption during the construction process. By eliminating the need for formwork and reducing the reliance on heavy machinery, energy requirements can be significantly reduced compared to traditional construction techniques.
  We look at the entire lifecycle of the building to understand the value in the embodied energy of a home.
  Using self-healing concrete with a high PSI, 3DCP buildings allow a lifespan of 1000 years, rather than 40-50 years of common lumber build.
  The embodied energy of 3DCP buildings are remarkably low when divided across even a conservative estimate of the building’s lifespan.
  These technological developments also increase insurability, lower maintenance costs, and allow homeowners to build generational wealth.
• Lower Carbon Emissions: Traditional concrete production is a major source of carbon dioxide (CO2) emissions due to the energy-intensive processes involved in cement manufacturing. However, 3D concrete printing offers the potential to optimize material usage, resulting in lower cement consumption and, consequently, reduced CO2 emissions associated with concrete production.
  The efficiency of the printing itself reduces the carbon footprint dramatically.
  We source Carbon Sequestering Concrete, which means the concrete absorbs carbon out of the air as it cures completely (first 8 months). Carbon Sequestering Concrete absorbs 50% of its weight in Carbon (splitting carbon dioxide and releasing oxygen). This means if a home is 24 tons of concrete, it will absorb 12 tons of carbon out of the air, making concrete a carbon negative product.
• Use of Recycled Materials: Some 3D concrete printing opportunities allow for the incorporation of recycled materials, such as aggregates from construction and demolition waste or industrial by-products like glass, fly ash or slag. By utilizing recycled materials, the environmental impact of concrete production can be further reduced, and the demand for virgin resources can be minimized.
• Design Optimization: 3D concrete printing enables the creation of complex geometries and optimized structures that use materials more efficiently. By designing structures with optimized material usage, it’s possible to reduce the overall environmental footprint of construction projects. This economy of form saves time and material, it can also produce beautiful shapes and spaces previously cost prohibitive in lumber construction.
• Localized Production: On-site or near-site 3D concrete printing can minimize transportation-related emissions by reducing the need to transport heavy precast elements or ready-mix concrete to construction sites.  This localized production approach can also enhance construction efficiency and reduce logistical complexities.
• Enhanced Durability: 3D printed structures can be designed to have enhanced durability and longevity, reducing the need for frequent maintenance and repair activities. This can contribute to overall resource efficiency and reduce the environmental impact associated with ongoing maintenance activities.

Overall, 3D concrete printing offers significant potential to improve the environmental sustainability of the construction industry by reducing material waste, energy consumption, carbon emissions, and reliance on virgin resources. However, continued research, development, and implementation of sustainable practices are essential to maximize the environmental benefits of 3D concrete printing technologies.

Can We Print the foundation? Floors?

Slab forms are printed and left in place after the slab has been poured. This allows considerable savings  in formwork, both in time and materials

This also eliminates blowouts or the need for backfilling. This brings incredible accuracy and speed to the layout process as each printed form will be dimensionally specific to its location.

• Fernie
• Global Forest Watch

• Concrete has been around for over 2000 years.
• We are applying an efficient and sustainable way to build with a traditional material.
• Traditionally in Hawaii stone foundations were common, and coral was used as an early binding material.
• Sedimentary coral deposits occur naturally and bind rocks together.
• This geological formation is evident on Hawaii’s west facing shores, like Lahaina.
• Our return to a rock and coral based building material echoes the solidity of Hawai’i’s ancient stone walls.

As of my last update in January 2022, the construction industry has indeed faced challenges related to labor shortages in various regions. These shortages can be attributed to several factors, including:

• Demographic Trends: Aging demographics in many developed countries have led to a decreasing pool of skilled workers in the construction industry.
• Skills Gap: There’s often a mismatch between the skills required by construction firms and the skills possessed by available workers, leading to difficulties in filling job vacancies.
• Cyclical Nature of Construction: The construction industry is cyclical, experiencing periods of high demand followed by downturns. During boom periods, there may not be enough skilled labor to meet demand.
• Immigration Policies: Changes in immigration policies and restrictions on foreign labor can also impact the availability of construction workers, particularly in regions where foreign workers play a significant role in the industry. Unlike what has been previously thought, studies show immigration labor fills most skilled labor positions. Without skilled labor, ‘traditional’ construction becomes cost prohibitive.
• Workforce Attrition: Many experienced construction workers are reaching retirement age, further exacerbating the labor shortage. The ability for skilled labor positions to attract young workers has diminished greatly without the sense of competition present during a population boom.

Regarding the rebuild of Lahaina, if there’s a labor shortage in the construction industry, it could potentially impact the pace and cost of the reconstruction efforts. A shortage of skilled workers may lead to delays in project timelines and increased labor costs as contractors compete for the available workforce.
We are seeing now, as Lahaina’s infrastructure is slowly being rebuilt that demands for the ~10,000 laborers and skilled craftsmen that would be needed to rebuild Lahaina within 3-5 years could cripple the current residents by focing competition, for housing, food, and basic necessities. Especially if this labor force had a desire to be with their families during this period. 

Having a robust construction solution that offers immediate structure erection with low demand on Lahaina’s resources is proving economical and responsible to Lahaina’s residents

To mitigate the effects of a labor shortage, various strategies can be employed:

• Investment in Training and Education: Increasing investments in training programs and vocational education to develop a local skilled workforce for the new construction industry.
• Technology Adoption: Embracing technological advancements such as 3D printing, robotics, and automation to improve productivity and reduce reliance on manual labor. Working directly with Hawaii’s unions to provide updated workforce training.
• Labor Connection: Encouraging the sharing of labor pools by facilitating the movement of workers from regions with surplus labor as needed for site specific tasks, leveraging remote workers and the resources of the neighboring Island of Hawai’i .
• Prefabrication and Modular Construction: Prefabrication and modular construction techniques can help mitigate labor shortages by reducing the need for on-site labor and speeding up construction processes. Using leading technology, and taking initiative to provide local training allows a time savings in construction estimates that are priceless for Lahaina.

Overall, addressing labor shortages in the construction industry requires a multifaceted approach involving collaboration between governments, educational institutions, industry stakeholders, and communities. In the case of the rebuild of Lahaina, navigating the challenges posed by labor shortages will be essential to ensure the timely and successful reconstruction of the area.

Time has become money for Lahaina’s residents as they live in uncertainty. Providing a building solution that greatly reduces labor also greatly reduces the time and the resources needed for that manpower. 
A ripple effect that will benefit Lahaina’s residents in the long run.

Often called self-healing concrete, buildings with these properties last thousands of years.  Homes span generations again, and provide resilience in changing times.

Here are some key features and characteristics of Roman cement:

• Composition: Roman cement was primarily composed of lime (calcium oxide), volcanic ash, and water. The volcanic ash, obtained from sources such as Pozzuoli near Naples in Italy, contained silica and alumina, which contributed to the cement’s hydraulic properties.
• Hydraulic Properties: One of the distinctive features of Roman cement was its ability to set and harden underwater or in wet conditions. This hydraulic property made it particularly suitable for the construction of structures such as aqueducts and harbors.
• Strength and Durability: Roman cement was known for its strength and durability, allowing Roman engineers to construct large and enduring structures that have stood the test of time.
• Versatility: Roman cement was versatile and could be used in various construction applications, including as a mortar for binding stones or bricks together, as a plaster for finishing surfaces, and as a structural material for building walls and vaults.
• Longevity: Many Roman structures built with Roman cement have survived for centuries, demonstrating the material’s longevity and resilience.
• Legacy: Although the specific recipe for Roman cement was lost over time, its use in ancient Roman construction has had a lasting influence on the development of modern cementitious materials and construction techniques.

While Roman cement shares some similarities with modern hydraulic cements like Portland cement, there are also significant differences in composition and manufacturing processes. Nevertheless, the legacy of Roman cement continues to inspire engineers and architects, and its historical significance remains an important aspect of the study of ancient Roman architecture and engineering.

• MIT News
• Advanced Functional Materials

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Plumbing and electrical can be run easily within the wall cavity. Outlet boxes and rough in for fixtures can be preprinted, with sleeves to allow wire and pex runs. Detailing will differ from project to project.

Patent Pending at this time.

Depending on shipping rates.

Preprinted walls are delivered onsite in manageable sections. Each section is designed to be easily placed with a forklift.  As the sections fit together their ends will collectively encase any rebar or hold downs and pumped concrete will grout the two panels together. This detail is copyright by law.

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Your content goes here. Edit or remove this text inline or in the module Content settings. You can also style every aspect of this content in the module Design settings and even apply custom CSS to this text in the module Advanced settings.

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