Layer by layer, the new Strabag BMTI (Strabag Baumaschinentechnik International) warehouse in Stuttgart's Weilimdorf district is growing upwards. Together with Putzmeister and its Karlos mobile concrete printer, Züblin has developed an innovative construction method that is unique in the world. As part of their long-standing collaboration, the two companies are pooling their innovative strength to take 3D concrete printing to a new level. The aim of their research is to be able to offer customers an even more flexible and sustainable printing process in the future.
The new technology is based on a truck-mounted concrete pump. An automatically controlled boom with a reach of 26 metres applies concrete in several layers using a special pressure head based on a predefined digital construction plan. In this way, storey-high, supporting concrete walls are produced that are room-sealing, i.e. prevent the spread of flames and smoke in the event of a fire. The main challenge of 3D concrete printing to date has been the lack of scalability of the technology for large-scale projects.
CO2-reduced concretes in use
The economic and ecological advantages of the method include the complete elimination of formwork, the production of solid wall cross-sections in a single operation and the use of CO2-reduced concretes. By using only green electricity for the all-electric machine and CO2-reduced concretes, Züblin and Putzmeister are making an important contribution to making building construction more sustainable in the long term.
“On our way to realising resource-saving and climate-neutral planning and construction, we are proud to have developed a highly innovative 3D printing process together with Putzmeister. As a construction group, we are contributing our expertise in the digital planning of building structures and concrete technology in particular to this pioneering innovation,” explains Züblin board member Stephan Keinath.
Putzmeister CEO Christoph Kaml sees Karlos as a central element of the company's strategy: “A high degree of electrification and automation is required along the entire work process. The reduction of manual labour is a decisive factor in dealing with the increasing shortage of skilled workers. As a digital technology of the future, Karlos is a central building block on the road to the construction of tomorrow.”
3D printing as a driver of productivity
Additive manufacturing methods, in particular 3D printing, have become an integral part of industries such as mechanical engineering, automotive and aerospace. Now they are also increasingly conquering construction sites. The combination of production steps from the digital planning of the BIM model (Building Information Modelling) through to realisation using 3D printers is revolutionising construction processes. Work processes are significantly streamlined and accelerated through automation.
About the Putzmeister Group
The Putzmeister Group develops and produces machinery of high technological quality in the fields of concrete conveying, truck-mounted concrete pumps, stationary concrete pumps, placing booms and accessories, plant technology, conveying viscous industrial materials through pipes, concrete spraying and transport in tunnels and underground, mortar machines, plastering machines, screed conveying, injection and specialist applications. Market segments include the construction industry, mining and tunneling, large industrial projects, power plants and sewage treatment plants, as well as waste incineration plants, all over the world. The company is based in Aichtal. With more than 3,000 employees, the company achieved a turnover of EUR 905 million in the year 2022.
About Ed. Züblin AG
Ed. Züblin AG, Stuttgart, employs around 15,000 people and is one of Germany's largest construction companies with an annual output of around € 4.5 billion. Züblin has been successfully realising challenging construction projects in Germany and abroad since 1898 and is the leading brand for building construction and civil engineering within the Strabag Group. The range of services covers all construction-related tasks - from complex turnkey construction, civil engineering and tunnelling to construction logistics, building maintenance, special civil engineering, timber and steel construction. Drawing on the expertise of its Central Technology Centre, Züblin also offers integrated planning and construction from a single source.