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In the heart of this Central Texas town, within the confines of The Halles event center, a robotic arm diligently constructs the walls of five cozy vacation rentals. Methodically, layer by layer, streaks of concrete are carefully laid, gradually forming the structure of these hidden getaways known as Round Top.
With over 200 listings on Airbnb, Round Top is well-acquainted with short-term rentals. Despite its population of less than 100 residents, the town’s antique events and vibrant live music scene attract numerous tourists.
Hive3D founder and CEO, Timothy Lankau, envisions a groundbreaking transformation in construction with the introduction of the Casitas at the Halles. These innovative additions are 3D printed homes primarily constructed by machines. Lankau’s Houston-based company, established in 2022, has already successfully built six homes.
Lankau expressed his disbelief at the housing crisis in America, considering it the most foolish crisis he could ever conceive. He found it astonishing that with the abundant ingenuity and resources available to us as a society, we have yet to devise a more efficient method of constructing walls and roofs to provide every individual with a comfortable home.
Despite being a new technology, Lankau and others venturing into this project are confident that 3D homes have the potential to alleviate the housing crisis while also being environmentally sustainable.
3D printing of residential structures is still a new concept. The first one, a 3,000-square-foot home in Yaroslavl, Russia, was completed in 2017.
One year later, Icon, a startup based in Austin, presented its inaugural 3D-printed construction at the technology segment of South by Southwest.
Tom vonReichbauer, the CFO of Icon, revealed that their main objective was to expedite the construction of a significant number of houses. After careful consideration, they decided to utilize 3D printing technology with a concrete-like material. According to him, advanced robotic construction holds the most potential for future progress. Icon is currently engaged in constructing an entire subdivision near Austin employing this innovative approach.
A small 3D-printed home’s walls can be built in under 24 hours, with printing on larger single-family homes’ walls ranging from 10 to 45 days.
The average single-family home using traditional methods takes six to eight months to construct, according to eXp Realty.
VonReichbauer explained that incorporating automated technologies and robotic construction into the field of construction can significantly reduce the time it takes to build a home. Additionally, this approach allows for the printing of houses with minimal waste, unlike traditional construction sites which tend to generate substantial amounts of waste.
Similar to traditional construction methods, the initial step involves laying the foundation. Following this, rebar is positioned to provide support for both the interior and exterior walls, which are subsequently printed over the rebar. The 3D printing machine’s robotic arm applies the cement in layers, akin to frosting, leaving an empty area for electrical wiring and plumbing that will be filled with additional concrete later on. Once a wall is finished, the robot is relocated to the next one. The completed walls exhibit a ribbed texture horizontally.
Once the walls have been completed, the next step is for workers to proceed with the installation of doors, windows, and a roof.
Both Hive3D and Icon use alternatives to portland cement — cement production is one of the biggest sources of greenhouse gases in the construction industry and is responsible for about 8% of the world’s CO2 emissions per year.
Hive3D collaborated with Eco Material Technologies, a Utah-based company specializing in the development of environmentally friendly alternatives to concrete known as “green cement.” This innovative cement incorporates fly ash, a commonly occurring byproduct derived from coal-fired power plants.
According to Grant Quasha, CEO of Eco Material Technologies, their mixes do not need limestone milling and heating like portland cement does. This process is responsible for a majority of the pollutants in the product. As a result, their mixes generate significantly fewer emissions, ranging from 92% to 99% less.
According to Quasha, the green cement does not possess a completely carbon-neutral footprint due to the need for transportation to the construction site and the electricity consumed by the milling process. However, the company asserts that its cement alternatives effectively prevent over 6 million tons of CO2 from being released into the environment annually.
Icon makes its own concrete alternative called Lavacrete, which vonReichbauer says uses some portland cement. He said the company is looking for ways to make it more eco-friendly.
Built for the climate
As Lankau strolled through Hive3D’s inaugural single-family home in Burton, situated approximately midway between Austin and Houston, he couldn’t help but notice the remarkable contrast in temperature. Despite the scorching August weather, the interior of the house felt noticeably cooler than the outside, all while astonishingly, the air conditioning system hadn’t even been installed yet.
According to Lankau, the homes are equipped with thick foamed concrete walls that contribute to an above-average R-value. This term signifies the material’s ability to resist heat transfer. Despite the escalating heat in Texas, the concrete construction’s insulation capabilities are expected to maintain cooler indoor temperatures, thereby reducing utility expenses.
According to Lankau, the inclusion of concrete walls enhances the homes’ resistance against powerful winds and ensures a higher level of safety during severe weather occurrences such as hurricanes and tornados.
Lankau stated that their preference is to construct buildings using curved shapes and minimize flat surfaces, as this reduces the resistance against wind. He further mentioned that the roofs are securely fastened to the foundation and reinforced with concrete rebar, making the structure highly resilient against strong winds.
According to Lankau, concrete structures have a higher chance of enduring floods without experiencing significant structural damage or mold infestation. In contrast, traditional frame homes usually necessitate extensive repairs when materials like sheetrock, insulation, and wooden framing are flooded with water.
According to Lankau, the presence of these foot-thick concrete walls in the house makes them impervious to bullets and other potential damage. The entire structure, from the foundation to the roof line, is made up of inorganic materials, which means there is no chance of decay or deterioration over time. As a result, the appearance of this house is expected to remain unchanged for the next century.
Addressing affordability and the shelter crisis
Lennar, a prominent developer based in Florida, is partnering with Icon to print an entire 100-home subdivision named Wolf Ranch, located approximately 30 miles north of Austin in Georgetown.
According to VonReichbauer, the city has shown remarkable openness towards our endeavors, and the initial properties were quickly sold within days of being listed.
Lennar is listing the homes for roughly $470,000 to $579,000; the average cost of a home in Georgetown sits at $459,932.
According to VonReichbauer, the company has partnered with New Story, an organization dedicated to addressing the worldwide shelter crisis, to construct 3D-printed houses in Mexico.
Ten homes were constructed just outside of Nacajuca in the state of Tabasco, according to New Story, which claims it to be the world’s inaugural 3D printed community. These houses were specifically designed for financially disadvantaged families in the area, who relocated and settled into their new homes in November 2021.
In addition, Icon collaborated with Mobile Loaves & Fishes in Austin to construct six 400-square-foot homes within an east Austin community managed by the nonprofit organization, catering to individuals facing chronic homelessness.
As Hive3D expands, Lankau envisions replicating his success by offering affordable housing options. He believes that his Round Top rentals, ranging from 450-square-foot studios to 850-square-foot two-bedrooms, can serve as a blueprint for constructing cost-effective homes in a state facing a burgeoning housing crisis.
According to Lankau, Hive3D will autonomously function as a developer when required, ensuring that their homes are offered at affordable prices. Additionally, Lankau aims for the company to cater to a diverse set of consumers in their sales approach.
Lankau stated that there are various levels of affordability, which include government-subsidized housing and housing specifically constructed for individuals with median incomes to afford. They are receptive to all options.
However, James Tate, an assistant architecture professor at Texas A&M University, expressed skepticism about the long-term ability of these companies to keep their prices affordable and compete in the Texas housing market.
Tate expressed that in this state, developers are not obligated to include affordable housing units and there are no incentives to do so, except for those developers who personally believe in promoting fair housing. According to Tate, housing discrimination is prevalent in this state as there are no strict measures to prevent it.
Tate holds doubts regarding the potential of 3D printing to revolutionize the construction sector and effectively tackle the housing crisis.
“As a researcher and design faculty member at a university, I cannot escape the yearning for optimism,” he expressed. “Nevertheless, my understanding of architectural and construction history compels me to acknowledge that with every endeavor aimed at resolving our housing predicaments, a new challenge inevitably arises. The influence of capitalism permeates all aspects of property and real estate.”
Todd Wiseman contributed to this story.
