Alquist completes 3D concrete printed expansion of Owens Cross Roads Walmart Supercenter

OWENS CROSS ROADS — Faster. Cheaper. Stronger.

Using innovative construction technology and setting industry speed and cost standards in the process, Alquist completed a groundbreaking 3D concrete printing expansion project at the Walmart Supercenter in Owens Cross Roads.

The walls supporting the 5,000-square-foot pickup expansion were completed in one week and addressed two of the construction industry’s biggest challenges: “takes too long” and “costs too much.”

The collaboration continues accelerating speed and cost-efficiency in commercial construction, setting the stage for future advances, Alquist said in a news release.

Alquist said its five-person team used two 3DCP systems to print the 16-foot-high walls in just 75 hours during seven operational days, significantly faster than traditional building methods.

“In a commercial construction world that pays so much attention to project timelines and costs, our work with Walmart shows that 3D printing isn’t just a novelty – it’s an innovation ready to scale,” said Alquist 3D CEO Patrick Callahan. “… we’re demonstrating how retail expansions can be faster, more cost-effective, and less wasteful, paving the way for broader adoption in large-scale builds.”

The Alquist 3DCP crew set a company record for a project this size, based on speed, and established a new benchmark for cost efficiency in commercial construction.

The 3DCP reduced overall costs for the project versus traditional construction, showing that costs can continue improving as usage scales to additional projects, underscoring the technology’s benefits to retail construction timelines and budgets, the company said.

“These tests aim to evaluate alternative techniques to traditional construction, while maximizing sustainability,” said LB Johnson, vice president of construction at Walmart. “Our approach to innovation is designed to optimize processes and simplify field operations – leading to reductions in project costs and timelines.

“This will enable speed to market for our customers and help accelerate evolution in the construction industry.”

Also, of particular interest in North Alabama, one of the most significant advantages of 3DCP is its resilience in adverse weather.

Alquist’s team showed a distinct advantage from traditional construction methods, having printed through weather conditions known to delay and halt traditional CMU block construction, allowing the project to proceed ahead of schedule.

FMGI, the general contractor, provided on-site coordination, ensuring the advanced 3D printing process worked seamlessly with conventional construction tasks. Sika USA supplied specialized concrete mixes formulated to deliver both speed and durability under real-world conditions.

“We’re proving that 3DCP is cheaper and greener than standard CMU construction,” said FMGI President and CEO Darin Ross. “This build cost 15% less and produced 55% less waste than the first 3DCP build late last year in Athens, Tenn.”