THE FUTURE OF CONSTRUCTION IN IRELAND

3D Construction Printing (3DCP), or Additive Construction (AC), is an emerging technology focused on enhancing efficiency, affordability, and sustainability in the construction industry

By leveraging cutting-edge 3DCP technology, it delivers robust buildings faster and more efficiently than traditional construction methods.

As Ireland encounters rising housing demands, a shrinking skilled labour force and increasing quality and consistency requirements, innovation is the only way to bridge such gaps. 3DCP addresses these issues by enabling the use of fewer labour and material resources to increase and accelerate housing productivity.

The Basics of 3D Construction Printing Technology
Classed as MMC Category 4, 3DCP is an additive manufacturing process where buildings are constructed on-site using a large-scale gantry printer. Guided by a digital model, the printer deposits concrete one layer at a time to form the building’s superstructure. The process minimises manual labour, reduces waste, and accelerates construction speed and consistency.

COBOD International, the leading manufacturer of 3D construction technology, supplies 3DCP equipment in projects across Europe, the Middle East, Asia, and the Americas. HTL.tech are COBOD’s exclusive distributor in Ireland and the UK. HTL.tech have partnered with Roadstone to develop low-carbon printable concrete and scale the technology for large-scale deployment, focusing on the Housing Sector.
With as few as 12 machines and 50 personnel, up to 1,000 new high-quality homes can be built annually.

Key Benefits of 3D Construction Printing
1. Speed and Efficiency
3DCP reduces construction timelines by 25% (from ground clearance to completion) and 60% (compared to traditional methodologies). Our Louth County Council project showed this with three two-storey homes, each 110sqm GIA. The printed structures required only 12 print days, totalling 18 working days on-site, which included 2 days for setup, 2 for scaffolding, 1 for floor joists, and 1 for equipment dismantling. In contrast, a traditional methodology program for this project would take 44 working days.
2. Quality
The concrete superstructures are 5 times stronger than standard element work (45 MPa compared to 8 MPa). With the end structure being most comparable to mass concrete, the resultant 3DCP superstructure is inherently airtight, fireproof, and offers excellent acoustic performance.
3. Precision
The technology in unique in enabling the accurate, reliable on-site transfer of digital models using concrete. Knowing the superstructure is precisely delivered allows coordination with subcontractors to prefabricate components like foundations, flooring, partitions, and roofs before site arrival; these can be installed within 12 hours post-printing. Moreover, it provides design flexibility for unique architectural forms that are difficult and expensive to achieve with traditional methods.
4. Sustainability and Waste Reduction
3DCP enables precise material placement, minimising waste and environmental impact. The efficient use of materials, low carbon concretes, and the structure’s longevity make this building method sustainable.

HTL.tech and Roadstone are currently working on a phase 2 detail, which focuses on utilising the concrete’s thermal mass to regulate heating and cooling requirements. This strategy is anticipated to help reduce operational inputs throughout the building’s lifecycle and further reduce carbon emissions.
5. Addressing Labor Shortages
The construction sector in Ireland is hampered by low productivity, estimated to be about 32% below the European average. These productivity issues, rooted partly in low investment and a reliance on traditional construction methods, contribute to labour demands. With nearly 80,000 additional workers needed to meet infrastructure needs, primarily in housing, productivity improvements could help achieve these targets without requiring a drastic increase in workforce numbers.

3DCP offers a promising solution by improving efficiency through automation and reducing reliance on manual labour. A standard 3DCP team consists of four roles: print operator, print assistant, pump operator, and materials assistant. This streamlined team setup highlights how 3DCP could enable Ireland to meet housing goals more efficiently and cost-effectively.

Since June 2022, Louth Meath Education & Training Board (LMETB) has offered specialised 3DCP training for Ireland’s construction workforce. In partnership with HTL.tech, this programme teaches practical skills in advanced 3DCP technology, reducing reliance on conventional labour and increasing productivity. The training aims to close the skills gap and promotes a technology-driven approach to Ireland’s housing and infrastructure demands.
6. Cost/Value
Currently, costs are comparable to those of traditional methodologies. However, 3DCP can improve overall contraction programmes by over 25% using similar financial resources and less labour. This translates into cost reductions on the overall project associated with less on-site time while providing greater project certainty.

Real-World Applications of 3DCP in Ireland
HTL.tech’s recent project illustrates the tangible benefits of 3DCP technology in the Irish context. Working with Roadstone Ltd., we are scaling up the technology and actively seeking projects ranging from 10 units to 100 plus.

The Grange Close social housing project in Dundalk, Co. Louth, exemplifies the effectiveness of 3DCP in addressing Ireland’s housing crisis. Collaborating with Louth County Council, Roadstone Ltd., and LMETB, this initiative shows how 3DCP integrates traditional materials like RMC with additive construction techniques and prefabricated MMC components. This project is the first 3DCP social housing initiative in Europe to use standardised RMC, highlighting HTL.tech and Roadstone’s role in promoting 3DCP technology within Irish industry standards.

Overcoming Obstacles and Building for the Future HTL.tech has addressed regulatory and material obstacles in 3DCP with Roadstone, ensuring compliance and optimising materials for safe, reliable structures. We achieved significant milestones, including conformity with the new Additive Manufacturing standard I.S. EN ISO/ASTM 52939:2023. In recognition of this achievement, HTL.tech received the ‘Standards Innovation Award’ from the National Standards Authority of Ireland (NSAI) in October 2024.

A New Future for Construction in Ireland Additive Construction is no longer an experimental technology—it is a practical, effective and proven solution for addressing critical challenges in the construction sector. As demand for housing and sustainable construction solutions continues to rise, adopting Additive Construction technology could be crucial in meeting these needs while reducing costs, minimising environmental impact, and ensuring high-quality structures for communities nationwide.

Through collaborations with industry leaders and continued advancements in AC, HTL.tech, COBOD International, and Roadstone look forward to making a meaningful impact by delivering rapid, high-quality housing in Ireland and beyond.

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Michael McDonnell Managing Editor of Irish Construction Industry Magazine & Plan Magazine

Email: michael@irishconstruction.com      WWW.MCDMEDIA.IE