OWENS CROSS ROADS, Ala.—Walmart and Alquist have completed another groundbreaking construction milestone with the expansion of the Owens Cross Roads Walmart Supercenter, utilizing cutting-edge 3D concrete printing (3DCP) technology. The 5,000-square-foot pickup expansion marks Alquist’s second 3DCP project for Walmart, continuing to push the limits of speed, cost savings, and sustainability in commercial construction.

Robots and 3D concrete printing by Alquist 3D built the walls of this 5,000-square-foot expansion. Using a robotic arm, Alquist layered concrete to form walls cheaper, three times stronger, and 50% faster than normal construction methods. This project follows Alquist’s first 3D-printed Walmart build completed in Athens, Tenn., late last year.

“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 Patrick Callahan, CEO of Alquist 3D. “With this second project, 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 five-person Alquist team operated two 3DCP systems to print the 16-foot-high walls in just 75 hours over seven operational days, shattering traditional timelines. A build of this size would normally take three weeks or more using standard methods.

Darin Ross, president and CEO of FMGI, Inc., the project’s general contractor, emphasized the efficiency gains. “We’re proving that 3DCP is cheaper and greener than standard CMU construction,” Ross said. “This build cost 15% less and produced 55% less waste than the first 3DCP build late last year in Athens, Tenn.”

The use of 3DCP not only improved speed and cost-efficiency but also yielded measurable sustainability gains. Material waste was reduced by 55%, setting a new benchmark of less than 5% waste overall. Thanks to precise printing and optimized material use, Alquist projected needing 130 bags of Sika concrete material but ultimately only required 94.

“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.”

Another key advantage of 3D concrete printing is its ability to operate under weather conditions that typically delay or halt conventional construction. Despite variable weather, the Alquist team was able to continue printing uninterrupted, keeping the project on schedule.

The robotics-driven approach also offered improved safety for workers by reducing the need for scaffolding and manual material handling. The five-person crew completed work that would have required a much larger team using traditional techniques, showcasing the labor efficiencies of technology-enhanced construction.

Beyond its immediate project goals, Alquist is investing in workforce development to ensure the future of this technology. The company’s 3DCP curriculum, developed with Aims Community College in Colorado, equips the next generation of builders with hands-on technical skills and innovation leadership, preparing them to manage and execute large-scale 3D printing projects.

The Owens Cross Roads build represents more than just an expansion of a Walmart Supercenter—it signals a shift in how major retailers and contractors approach construction challenges in cost, speed, sustainability, and labor.

As Alquist and Walmart continue exploring 3DCP’s potential, more projects are expected to follow, paving the way for broader industry adoption of faster, cheaper, greener construction methods.

For more information about Alquist 3D and its projects, visit www.alquist3d.com.

Originally reported by Business Wire.