Europe’s first 3D printed social housing project fully compliant with the international ISO/ASTM 52939:2023 standard has been built in Ireland using COBOD’s BOD2 3D construction printer.

The use of the 3DCP technology meant 35% faster construction and completion in just 132 days compared to conventional methods requiring more than 200 days, with the 3D printed superstructure completed in just 12 printing days.

Load-bearing double cavity walls of 10 cm (3.9 inches) each with no reinforcement printed in accordance with EN206, Eurocode 6 for unreinforced masonry construction and ISO/ASTM 52939:2023.

Award-winning innovation recognized by the National Standards Authority of Ireland for advancing quality and sustainability in 3D construction printing.
Harcourt Technologies Ltd (HTL.tech) has constructed the Europe’s and the world’s first social housing project compliant with the ISO/ASTM 52939:2023 standard for additive manufacturing, which Ireland has adopted. Using COBOD’s BOD2 3D Construction Printer, the project demonstrates how 3D construction printing is addressing housing needs efficiently while meeting codes and the ISO/ASTM standard.

This quality assurance requirements outlined in the internationally recognized ISO/ASTM 52939:2023 standard ensure that 3D printed structures adhere to the same safety and performance benchmarks as traditional construction methods. This achievement represents a significant step toward establishing 3D construction printing as a recognized construction method.

HTL.tech’s work has been recognized with the Standards Innovation Award by the National Standards Authority of Ireland (NSAI). Geraldine Larkin, CEO of NSAI, highlighted this achievement, stating: “This honour recognises HTL.tech’s exceptional integration of standards into HTL Technologies’ processes for 3D house construction printing. Their innovative efforts are helping to position Ireland as a leader in this field and demonstrating how standards can drive cutting-edge advancements. By adopting I.S. EN ISO/ASTM 52939:2023, HTL.tech are setting a remarkable example for others in the industry to follow.”

The three-unit terraced social housing project, located in Grange Close, Ireland, has a total floor space of 330 m2 (3,552 ft2), with 3 apartments of 110 m2 (1,184 ft2) each. The entire project was completed in just 132 working days, from initial site preparation to the handover of keys. Compared to the 203 days typically required for traditional construction methods, this represents a 35% reduction in build time. Approximately 50% of the time savings came directly from 3D printing the wall system. The remaining savings were achieved through the precision of 3D construction printing, which enables seamless integration of other building components – such as partition walls, floor systems, and trusses – to already be considered during the planning and preparation phases, resulting in a more efficient construction process.
Justin Kinsella, Director of HTl.tech, said: “HTL.tech is extremely proud to be the first company in Europe to build a structure that complies with the rigorous new I.S. EN ISO/ASTM 52939:2023 additive manufacturing standard, representing a significant advancement in additive construction. The COBOD BOD2 3D printer was crucial in this accomplishment, enabling us to complete the Grange Close Social Housing Scheme 35% faster than traditional methods. The BOD2 printer’s precision and efficiency, combined with complementary Modern Methods of Construction (MMC) technologies, allowed us to establish new industry standards and offer an effective means to produce high-quality, sustainable housing at an accelerated rate.”

The walls of the Grange Close project were printed using the BOD2 3D Construction Printer in only 12 printing days. Including setup and takedown of the printer and scaffolding, the entire structure was completed in 18 days. This is almost 1 month faster than if conventional methods of construction had been used.
3D construction printing with the COBOD BOD2 decreased the completion time for the entire project by 35% and the wall construction time by 59.1%, from 44 days to just 18!

The load bearing wall system, designed to meet the Eurocode 6 masonry standards, consists of two 10 cm (3.9 inches) thick load-bearing concrete walls with a 150 mm cavity, eliminating the need for steel reinforcement or columns. The structure used 90 m3 (3,718 ft3) C30/37 EN206 compliant concrete, with a compression strength of 47 MPa to ensure durability and strength.

Since project completion, HTL.tech has also made significant further advancements to their printing process. During the project COBOD upgraded the concrete hose of the BOD2 to a 65 mm hose, increasing volumetric output by 40%, and significantly increasing the printing speed of HTL.tech. An upgrade that now is available to all COBOD’s customers. With this upgrade, HTL.tech projects to be able to reduce the printing times for similar structures from 12 days to just 9 days, when the whole project is made with a 65mm hose.

Henrik Lund-Nielsen, General Manager and Founder of COBOD International, stated “We congratulate HTL.tech on their success! This award is a testament not only to HTL.tech’s professionalism but also to the potential of 3D construction printing in terms of increasing execution time, cutting down on labor and produce high quality constructions in accordance with international standards. We continue to improve our technology and although a hose update can be seen as a small step, the numbers from HTL.tech proves that it is not.”

The methodologies and protocols developed during the Grange Close project are adaptable for other EU countries where the ISO/ASTM 52939:2023 standard applies. HTL.tech plans to apply the lessons learned from Grange Close to future developments, paving the way for more efficient and sustainable housing projects across the region.
www.cobod.com

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