Walmart and Alquist Complete 3D Concrete Printed Expansion of Alabama Supercenter: Revolutionizing Retail Construction
In a groundbreaking development for the construction industry, Walmart and Alquist have successfully completed the expansion of the Owens Cross Roads, Alabama Supercenter using innovative 3D Concrete Printing (3DCP) technology. This marks the second project in their collaboration aimed at addressing two of the biggest challenges in commercial construction: time and cost. By leveraging advanced 3DCP systems, the team has set new benchmarks for speed, efficiency, and sustainability, paving the way for broader adoption of this transformative technology.
Record-Breaking Speed and Cost Efficiency
The 5,000-square-foot pickup expansion at the Alabama Supercenter was constructed in just seven operational days, with the 16-foot-high walls printed in an impressive 75 hours. A five-person Alquist crew utilized two 3DCP systems to achieve this feat—significantly faster than traditional building methods. According to Patrick Callahan, CEO of Alquist 3D, “In a commercial construction world that prioritizes timelines and costs, our work with Walmart demonstrates that 3D printing is not just a novelty—it’s an innovation ready to scale.”
This project underscores the scalability of 3DCP technology, as it reduced costs by 15% compared to conventional concrete masonry unit (CMU) construction while producing 55% less waste. These results build on the success of Alquist’s first 3DCP project in Athens, Tennessee, further proving that the technology becomes more efficient and cost-effective with each use.
LB Johnson, Vice President of Construction at Walmart, highlighted the company’s commitment to innovation: “Our approach aims to evaluate alternative techniques to traditional construction while maximizing sustainability. By optimizing processes and simplifying field operations, we’re reducing project costs and timelines, enabling faster delivery for our customers and driving industry evolution.”
Key Benefits of 3DCP Technology
The Owens Cross Roads project showcases several advantages of 3DCP technology, making it a game-changer for retail and commercial construction:
- Material Efficiency: The project achieved a remarkable reduction in material waste, cutting it by 55% and setting a new standard with less than 5% overall waste. Alquist projected using 130 bags of Sika material but only required 94, thanks to precision printing.
- Labor Optimization: Advanced robotics enabled a small, five-person crew to complete tasks traditionally requiring larger teams. This not only improved deployment speed but also ensured consistency and quality across the project.
- Enhanced Safety: On-site robotics eliminated the need for traditional scaffolding and bracing techniques, significantly reducing safety risks for workers.
- All-Weather Resilience: Unlike conventional CMU block construction, which is often delayed by adverse weather, 3DCP proved resilient in challenging conditions. The ability to print through inclement weather allowed the project to stay ahead of schedule.
Collaboration Drives Success
The success of this project was made possible through close collaboration between key partners. FMGI, Inc., the general contractor, provided seamless coordination between the advanced 3DCP process and traditional construction tasks. Sika USA supplied specialized concrete mixes designed for both speed and durability, ensuring the printed structures could withstand real-world conditions.
Darin Ross, President and CEO of FMGI, emphasized the financial and environmental benefits: “This build cost 15% less and produced 55% less waste than standard CMU construction. It’s clear that 3DCP is not only cheaper but also greener, offering a sustainable solution for the future of construction.”
Building a Future-Ready Workforce
As demand for advanced construction methods grows, Alquist is committed to workforce development through its comprehensive 3DCP curriculum—an integral part of the Alquist Ecosystem. Developed in partnership with Aims Community College in Greeley, Colorado, this program equips workers with the skills needed to execute and manage large-scale 3D printing projects.
By combining hands-on technical training with a focus on innovation, the curriculum ensures that the next generation of builders is prepared to embrace the transformative potential of 3DCP. This initiative not only strengthens the construction industry but also addresses the growing need for skilled labor in emerging technologies.
A New Era in Retail Construction
The completion of the Owens Cross Roads Supercenter expansion represents a significant milestone in the evolution of retail construction. By demonstrating the speed, cost-efficiency, and sustainability of 3DCP, Walmart and Alquist are leading the charge in redefining how commercial spaces are built.
This project proves that 3DCP is more than just a futuristic concept—it’s a practical solution that addresses the pressing challenges of today’s construction industry. As the technology continues to evolve, it holds the potential to revolutionize not only retail expansions but also broader applications in commercial and residential construction.
Why This Matters for the Industry
For businesses seeking to expand quickly and cost-effectively, 3DCP offers a compelling alternative to traditional methods. By reducing timelines, lowering costs, and minimizing environmental impact, this technology aligns with the growing demand for sustainable and efficient construction practices.
Walmart’s commitment to testing and implementing innovative solutions like 3DCP highlights its leadership in driving industry progress. As other companies follow suit, the adoption of 3D printing in construction is poised to accelerate, transforming the way buildings are designed, constructed, and maintained.
