Large-Scale Architectural Structure

November 2024

NEOM, Saudi Arabia

Wetland Project - NEOM – Design & Construction

Case Study: 3D Concrete Printed Massive Pergola Structure

Structure Weight
3.3 tons

Dimensions
3.2 × 2.8 × 1.85 m

Overhang Challenge
Approx. 40°

Printing Duration
3 days

Complex Geometry in Real Construction:
This project involved the design, fabrication, and installation of a large-scale 3D printed pergola with a challenging overhang geometry that pushed beyond typical concrete printing limits.

Advanced Structural Problem-Solving:
The pergola required an overhang of approximately 40°, while standard 3D concrete printing systems generally support around 20°. This made the project a strong demonstration of engineering-led additive construction rather than standard-form printing.

Sustainability-Driven Site Application:
Installed as part of a wetland environmental development in NEOM, the pergola contributed to a broader landscape and infrastructure concept focused on wastewater treatment, ecological landscaping, and circular water management.

Design-to-Installation Execution:
Delivered the pergola as a complete end-to-end project including structural design strategy, 3D printing, transportation, and on-site installation.

Specialized Printing Strategy:
Applied overlap layer printing, integrated lifting-base design, polymer mesh reinforcement, rebar reinforcement, and staged epoxy bonding to support the structure’s geometry and long-term stability.

Controlled Multi-Day Fabrication:
Printed the 3.3-ton structure over three days to reduce deformation risk, improve curing performance, and maintain print accuracy across each phase.

Real-Time Engineering Decision-Making:
During printing, the team identified a structural crack, paused the process, reinforced the affected area, and resumed only after sufficient curing strength was achieved, preventing failure and material loss.