Baskenweg’s prefabricated 3D printed condo facade nears completion

In one of the most significant ongoing 3D construction printing projects, Dutch company Bruil has conceptualized, fabricated, and supplied an array of intricate 3D printed concrete components for the Baskenweg building in Den Helder. This initiative underscores the vast potential of 3D concrete printing, showcasing its versatility in freeform design, scalability, and intricate detailing.

Den Helder is home to a groundbreaking undertaking—the complete exterior enhancement of 154 apartment units using 3D printed concrete components. This marks a world first in the realm of architectural renovation. Nearly 1,200 prefabricated elements, ranging from 2 to 12 square meters, are being installed, revitalizing two previously monotonous, gray structures into modern and visually compelling edifices.

“This initiative represents an unparalleled opportunity to apply 3D concrete printing on an unprecedented scale,” explained Theo Voogd, Bruil’s Market and Innovation Manager. In the Den Helder project, the printing apparatus will generate no fewer than 30 facade components per week—an output rate that aligns seamlessly with the construction schedule. “Beyond its innovative aspects, this approach is inherently sustainable, eliminating the need for disposable molds and drastically reducing concrete waste.”

Last December, Bruil Prefab Printing inaugurated an advanced manufacturing facility in Veenendaal. Equipped with a cutting-edge robotic system, this facility fabricates concrete facade sections, balustrades, and columns. These components eschew traditional rigid forms in favor of fluid, undulating contours.

In collaboration with Kokon Architectuur & Stedenbouw and Helder Vastgoed, Bruil spearheads one of the most ambitious 3D concrete printing projects globally. Originally erected in the early 1970s, the two seven-story Baskenweg apartment buildings will receive a sophisticated Mediterranean-inspired aesthetic, enhanced by the addition of significantly larger balconies—an upgrade long desired by the residents.

Bruil has devoted approximately four years to perfecting this technique and constructing the specialized facility. The colossal robotic printer traverses the production hall via an integrated rail system, enabling the daily creation of bespoke architectural components.

Ton op ‘t Ende, Real Estate Manager at Helder Vastgoed, elaborated on the decision to implement 3D concrete printing: “At a critical juncture, we had to decide—allow the buildings to stand for another decade before demolishing them or upgrade their exteriors to extend their lifespan by an additional 40 years. The latter proved the most sustainable option, significantly outpacing new construction in both affordability and efficiency.” Comprehensive testing validated that the 3D printed concrete elements are durable and on par with, if not exceeding, conventionally cast concrete.