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New technology takes 3D concrete printing to the next level

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 roomsealing, 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. Until now, printing has primarily been carried out using so-called gantry printers, which
are limited to the production of smaller buildings. Compared to other concrete printing processes, KARLOS
has greater flexibility and range as a mobile construction machine and therefore also offers the potential for
scalability 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.
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‘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,’ says Christoph
Kaml.

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. As ground-breaking as the technology of 3D
printing is, the human factor remains crucial for the successful realisation of construction projects. We are
therefore also countering the massive shortage of skilled labour with the use of modern technologies. This not
only increases productivity, but above all also enthusiasm for an exciting and promising construction profession
with a bright future.

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