Led by Senior Lecturer Dr. Du Hongjian of the National University of Singapore, researchers at NUS are advancing the use of 3D concrete printing for structural applications in real construction settings. Working alongside Associate Professor Pang Sze Dai and industry partners, the team has demonstrated that additive manufacturing can move beyond architectural features and non load bearing elements to produce reinforced structural components suitable for Singapore’s dense urban environment.
Bong, S. H., Zhao, Y., Gao, Y., & Du, H. (2026). High-volume glass powder cementitious material for low-carbon concrete additive manufacturing. Construction and Building Materials, 513, 145431. https://doi.org/10.1016/j.conbuildmat.2026.145431
Singapore’s construction sector operates under persistent constraints, including limited land, tight project timelines and growing pressure to reduce reliance on manual labour. Over the past decade, 3D concrete printing has attracted attention for its formwork free fabrication and automation potential. However, most implementations globally have remained confined to façade elements, partitions or low rise structures. The NUS team focused instead on integrating printable concrete with conventional structural systems so that load bearing elements could be fabricated with greater design flexibility and material efficiency.
Dr. Du Hongjian of the National University of Singapore, stated,
“We are working with the NUS team to identify and develop further applications of 3DCP for other projects and potential use cases. By testing the technology in real project settings, we can better understand its practical requirements, cost implications and scalability, which are critical for responsible adoption in the industry.”
The research addressed both material formulation and construction workflow. Printable concrete mixes were engineered for extrusion stability, buildability and compatibility with reinforcement strategies required for structural performance. At the same time, the researchers developed a fabrication process aligned with existing prefabrication and on site practices. Laboratory testing and large scale trials evaluated the structural behaviour of reinforced printed components. Reported results indicate that these elements met required load bearing standards while using less material than comparable conventional components. Industry assessments cited manpower savings exceeding forty percent and efficiency gains of more than sixty percent for complex elements, alongside estimated material reductions of about thirty percent.
A significant milestone came in August 2025, when structural elements were printed on site in collaboration with the Singapore based contractor Woh Hup. The trial was verified by the Building and Construction Authority, marking the first on site structural 3D concrete printing exercise in the country. Project data indicated a reduction in man hours of roughly fifty percent compared with conventional construction methods. A second on site trial commenced in January 2026 to further assess buildability, quality control and scalability under operational conditions. Support from the National Additive Manufacturing Innovation Cluster helped facilitate large scale testing and engagement with industry stakeholders.
Alongside structural validation, the researchers are addressing the environmental profile of printable concrete. One challenge associated with 3D concrete printing is the relatively high cement content typically required to achieve pumpability and early strength. In a study published in Construction and Building Materials, the NUS team reported a 3D printable mix in which sixty percent of ordinary Portland cement was replaced with recycled waste glass powder. Full scale printed elements achieved compressive strengths exceeding fifty megapascals, a level suitable for structural use. Compared with conventional printable concrete, the revised formulation demonstrated reductions in embodied energy of approximately forty four percent and carbon dioxide emissions of about fifty two percent. Improved resistance to chloride penetration was also observed, suggesting potential durability benefits over time.
These developments align with Singapore’s broader efforts to modernise its built environment sector through automation and resource efficiency. Rather than positioning 3D concrete printing as a wholesale replacement for reinforced concrete, the research frames it as a complementary method that may be particularly suited to geometrically complex or labour intensive components. By validating structural performance under regulatory oversight and real site conditions, the project provides a test case for how additive manufacturing can be integrated into mainstream construction practice.
Adrian graduated with a Masters Degree (1st Class Honours) in Chemical Engineering from Chester University along with Harris. His master’s research aimed to develop a standardadised clean water oxygenation transfer procedure to test bubble diffusers that are currently used in the wastewater industry commercial market. He has also undergone placments in both US and China primarely focused within the R&D department and is an associate member of the Institute of Chemical Engineers (IChemE).
