Concrete is ever present around us. From houses, offices, and school buildings to shops, dams, bridges, sidewalks, and roads, concrete helps build structures that we use every day.
It’s not a new material by any stretch. In fact, the earliest recording of concrete structures dates back to 6500 BC in regions of Syria and Jordan. Then, of course, we have Romans who made extensive use of concrete in their construction. And now, eons later, many of these structures stand tall even today.
Over the years, the usage of concrete has only grown, with the global concrete market standing at $687.2 billion in 2021. It is further expected to grow to $821.6 billion by 2026, demonstrating the role concrete plays in our lives.
This expansion is driven by the growth of the construction industry as well as the increasing investment in new construction projects around the world. Economic growth and rapid urbanization also contribute to the rising demand for residential and commercial complexes across the globe. As cities grow, so does the need for infrastructure and, with that, the need for concrete.
While we know that there’s continued demand for cement, and it has been for ages, why is it so popular in the first place? And is it all good? Well, let’s find out!
Concrete: The Dangerous Need of the World
Before understanding what makes concrete so valuable, let’s see what exactly it is. It is a mixture of cement (or lime), water, and aggregates, which are a set of natural or artificial particles like sand, gravel, or crushed rock.
Here, cement, which is a manufactured mixture of calcium, iron, silicon, and aluminum, among other ingredients, is the binding material that gives concrete hardening properties, while water activates the cement to form a dense material.
What makes this composite material so valuable is its properties, including malleability—the ability of freshly mixed concrete to be molded into almost any shape—and durability—meaning it can last for many years. This affordable material can further be tailored to meet different construction needs.
Other attractive properties of concrete include its ease of use, strength, and ability to withstand not just heavy loads and compressive stress but also harsh weather conditions and natural disasters like earthquakes and hurricanes.
Then, there’s concrete’s ability to retain heat, fireproof, and easy to repair if any damage occurs. All these properties make cement a highly valuable product, leading its usage to skyrocket.
When it comes to concrete use cases, it has various applications in the construction industry. Concrete is actually the most widely used construction material in the world after water. It is used for building dams, bridges, highways, airports, roadways, canals, reservoirs, and pavement, along with residential buildings, commercial complexes, and other load-bearing structures.
To put it simply, concrete is a fundamental material in construction, playing a crucial role in shaping the infrastructure around us.
But that’s not to say that concrete has only benefits to offer. In fact, it is extremely dangerous.
For starters, cement is responsible for 1.6 billion metric tonnes of carbon dioxide (CO2), which amounts to about 8% of global CO2 emissions. And the extensive dependence of the construction sector on cement exacerbates its immense carbon footprint.
Meanwhile, the manufacturing of ordinary Portland cement (OPC) is responsible for 5% to 8% of global anthropogenic CO2 emissions. When extrapolated for all construction-related activities, the latest research shows an alarming picture, with almost 40% of energy-related CO2 emissions coming from this sector, which consumes 36% of the world’s final energy.
This is extremely concerning because CO2 emissions are projected to reach a record high of 37.41 GtCO2. CO2 emissions are also the primary cause of global warming, and according to IPCC, global warming at its current rate is anticipated to reach 1.5 °C above pre-industrial levels between 2030 and 2052.
Given the environmental ramifications of concrete, while its annual consumption rate amounts to 30 billion tonnes and is expected to rise perpetually, it’s important that everyone, from innovators to organizations and government, address this issue head-on.
Advancing Construction with 3D Printing
Concrete, as we noted above, is a necessary evil because while it has some great benefits and is crucial for civilization, it is really harmful to the planet, which is already dealing with deforestation, climate change, biodiversity loss, and so much more.
Add concrete to the mix, and things will just get worse. But what if there’s a way to address the harmful effects of this popular construction material?
Well, for one, the concrete is evolving to meet the complex and advanced needs of the world. As we previously shared, advanced materials like graphene and hemp are being increasingly utilized in construction materials. Even carbon-free cement is produced by replacing limestone or using fossil fuel-based limestone.
There’s another solution, and that’s 3D printing. That’s right! The very same method that is being used to create art, furniture, and other consumer products, along with forensics, prosthetics, and surgery, is also changing the game for construction.
3D printing or additive manufacturing, which involves making three-dimensional objects from a digital file by laying down layers of material, has been gaining a lot of traction thanks to its benefits of rapid prototyping, customization, cost savings, reducing material waste, fostering innovation, and sustainability.
This technology is now being utilized in construction, which isn’t anything new in itself, as 3D printing was first used in construction many decades ago. However, the use of 3D printing has grown significantly in recent years to accelerate the process significantly, optimize material usage, explore intricate designs and tailored structures, facilitate remote construction, and enhance safety.
The multifaceted benefits of 3D printing further include shorter supply chains due to on-site construction and a substantial decrease in workplace hazards due to reduced need for manual labor in high-risk operations.
This year, we actually saw the world’s largest 3D-printed neighborhood in Texas near its completion after being two years into construction. 3D-printed construction company ICON is behind this project.
A private company, ICON not only prints residential homes but is also involved in defense and off-world construction. Less than a decade ago, ICON raised a total of $451 million, which has increased its valuation to about $2 billion. The company is actually contracted by NASA to build landing pads, shelters, and other structures on the Moon as part of the agency’s Artemis Moon exploration program.
In 2018, it built the first permitted 350-square-foot 3D-printed home in the U.S., which only took two days. The house was built using concrete because, as ICO CEO Jason Ballard stated:
“It’s one of the most resilient materials on Earth.”
For its Texas community, the company is using its Vulcan printer, which is much like a regular desktop 3D printer, and pipes layer by layer. The difference with this Vulcan printer is that it is 45 feet wide and weighs 4.75 tons.
As for its process, concrete powder is mixed with sand, water, and other additives and then pumped into the printer. The concrete mixture is then squeezed out by a nozzle onto a brush, which builds up layer by layer following a pre-programmed path.
The robotic printer has built 100 3D-printed houses in what it says is the world’s largest 3D-printed community. With 3D printing being faster, less expensive, minimizing construction material waste, and requiring fewer workers, it is bringing “a lot of efficiency to the trade market,” as per the company.
This is just the beginning, though, as evident from the growth the 3D printing construction market is expected to see. Valued at $5.5 billion last year, the global 3D printing construction market is projected to grow at a CAGR of 105.8% to reach a whopping $3.3 trillion by 2032.
These numbers may seem mind-boggling at first, but as we shared in our previous article, 3D printing could emerge as a potential solution to the grievous problem of housing shortage, which makes the trillion-dollar target a real possibility.
Given the tremendous interest in 3D printing construction, it also makes sense to utilize this technology to change the construction market for the better. And that’s exactly what scientists from Nanyang Technological University (NTU) of Singapore are doing.
The researchers went yet another step further or deeper by 3D printing the concrete itself. For this, they have developed a 3D concrete printing method that captures carbon, showcasing a new way to reduce the environmental impact of the construction industry.
Click here to learn if 3D printing can help us tackle housing shortage.
3D Printing Concrete that Captures CO2
Earlier this month, NTU scientists published their research on “Carbon capture and sequestration with in-situ CO2 and steam-integrated 3D concrete printing.”
The research detailed the innovative method that aims to reduce the carbon footprint of cement significantly by cutting down the material usage, labor requirements, and construction time.
It is also suggested that sustainable development through 3D concrete printing may add as much as 5% reductions in global energy usage. These environmental benefits are potentially equal to its ability to streamline construction processes.
However, mixing CO2 in concrete, as the latest study does, has been done before with an aim to improve the quality of the material and help bring down cement’s negative environmental impact.
Early studies have already shown improvements in the mechanical properties of concrete through direct batch mixing with CO2 and exposing concrete to CO2 during production in carbonation chambers due to forming a “carbonation shell.”
Previous studies have reported an almost 15x increase in penetration resistance and as much as 1.16% carbon absorption in just half an hour of mixing mortar with CO2. Adjusting the accelerated carbonation curing (ACC) further showed a 1.98–25.5% carbon absorption.
While research on 3D concrete printing has largely focused on designing green cementitious mixtures to reduce its carbon footprint, the latest study noted that a few have considered advancing processing technologies, particularly to enhance its bulk carbon capture and storage capacity (CCS).
Studies on the carbonation of cementitious materials, particularly the minimal focus on depths, the researchers noted, are why their scaled implementation raises validity concerns. Not to mention, chamber-confined CCS solutions face limitations in terms of hardware and energy consumption when applied with 3DCP. As a result, the benefits of scalable, automated, and on-site construction are compromised.
This creates a need to develop an artificial carbonation process for 3D concrete printing that goes beyond traditional curing techniques.
As a result, the NTU researchers developed a new process to study its efficacy at sequestering carbon dioxide.
The newly developed technology involves a two-step extrusion-based system. The first step is injecting CO2 and steam into the mixing concrete. The mixture then directly incorporates and stores the CO2 in the concrete structure. The CO2 and steam in question are captured as the by-products of industrial processes.
This new approach demonstrated an increase of 38.2% in bulk carbon uptake, offering yet another way to achieve decarbonized construction by 3D printing concrete.
The design of the proprietary printhead attachment, which facilitates the regulated injection of gaseous and liquid additives, seeks to tackle the critical issue of environmental sustainability concerns with automated construction. It also addresses the issue of set-on-demand requirements but, most importantly, a lack of readily available CCS solutions that are compatible with 3D concrete printing.
Not only does the new way reduce cement’s carbon footprint, but it has also been shown to improve the mechanical properties of the concrete. This, in turn, offers great strength to the structure in comparison to traditional 3D-printed concrete.
According to the research paper, the CO2 and steam integration resulted in an increase of up to 50% in 3D printability, 45.3% in flexural strength, and 36.8% in compressive strength.
The researchers concluded that the samples that were exposed to CO2-steam integrated printing and open-air curing got the highest carbon uptake. According to the researchers:
“The presented solution offers a promising pathway towards decarbonized construction while expanding viable options for CCS beyond traditional confined curing methods.”
The team further pointed out the optimization of printing configurations, mix designs, and the injection of flue gases to reduce pure carbon dioxide feedstock wastage as possible areas for future research.
Investable Company in 3D Printing Space
Now, let’s take a look at a publicly traded company involved in the 3D printing market, which is estimated to be worth $17.5 billion in 2024 and is projected to grow at a CAGR of 16.4% to $37.4 billion in the next five years, that’s making advances in the sector and helping change the world for the better.
1. Stratasys Ltd. (SSYS -1.04%)
Stratasys is a popular name in the 3D printing space, and it provides solutions across multiple sectors. Technologies from the company have been contributing to advancements in the 3D printing field.
With a market cap of $689.5 million market cap, Stratasys has its shares currently trading at $9.66, down 32.35% this year. The company has an EPS (TTM) of -1.32 and a P/E (TTM) of -7.30.
For Q3 of 2024, Stratasys reported revenue of $140.0 million, up from $162.1 million recorded in the same quarter last year. With these numbers, the company’s recurring consumables revenue has been seeing year-over-year growth for eight straight quarters now, which it stated “reflects continued strong printer utilization.”
Stratasys Ltd. (SSYS -1.04%)
The growth of the GAAP gross margin of Stratasys improved to 44.8%, while its GAAP net loss came in at $26.6 million, and non-GAAP net income started to achieve profitability. $4.5 million of cash was reported to be used in operations, and YTD’s operating cash flow remains positive.
With these strong numbers, Stratasys raised its outlook for the full year 2024. As per that; it reported $580 mln in revenue of $570 million, Non-GAAP net income of $5 million, and capital expenditures of $20 million.
“We have successfully begun to transform the company through cost optimization and by focusing on higher-growth opportunities.”
– CEO Dr. Yoav Zeif said at the time
He further noted that the company’s main F3300 platform is getting a lot of attention while it continues to expand into its main target sectors, including healthcare, automotive, and aerospace.
According to Dr. Zeif, the company’s restructuring plan will help deliver $40 million in annual cost savings from next year.
“We are well-positioned to deliver increased revenue growth, profitability and cash flow in 2025, to address the pent-up demand once market conditions improve.”
– Dr. Zeif
Click here to learn all about investing in Stratasys Ltd.
Conclusion
Concrete has been a cornerstone of human development for centuries, but it is not without its dangers. The environmental impact of concrete is becoming a grave concern, creating an urgent need to find better solutions. The latest technology from NTU researchers is one such development that is going in the right direction. By utilizing additive manufacturing principles, 3D concrete printing has redefined traditional operations and promoted sustainability.
As the world struggles with urban expansion and climate change, innovations like 3D concrete printing can help the world meet the growing and complex needs of construction while mitigating its harmful effects. And though challenges remain in scaling and standardization, over time, as technology improves and gets widely adopted, 3D printing can play a key role in shaping tomorrow’s infrastructure.
Click here for a list of top additive manufacturing and 3d printing stocks.
