3D-Printed Concrete Wall System Features and Performance
Wall System
The Wall System is a high-performance 3D-printed concrete wall assembly engineered to deliver superior strength, energy efficiency, and design freedom. The system
extrudes precise, layered wall geometries that serve as the building’s primary load-bearing structure.
A Look Inside
internal
External
Core Highlights
- inner/outer shell
- fullY reinforced core
- Electrical Lines
- Water Lines
- Insulation
Type
The Icon Wall System
Wind Resistance
HURRICANE FORCE WINDS
Fire Resistance
+2 Hours
Third-party Certification
ICC-ES AC 509
Engineering Service Report 4652
Material used
Formcrete with Printed reinforcement
Thermal performance
0.056 btu/h·ft²·°F (R-18)
* Based on 10 ft Wall, Core 4 ft O.C. with Wood Structure at the top of wall
The WALL SYSTEM
The ICON wall system combines advanced 3D-printed concrete construction with high-performance spray foam insulation to deliver superior thermal efficiency. The dual-bead printed shell creates an insulated cavity that minimizes thermal bridging while maintaining
structural integrity.
Features:
- 3D-printed FormCrete Shell: Durable, precision-manufactured concrete envelope
- Cavity Insulation: Injection open-cell spray foam for complete thermal barrier
- Configurable Core Spacing: 4ft on-center structural cores
- Bond Beam Integration: Solid Concrete sections for floor and roof connections
- Cross-tie Reinforcement: Steel ties connecting inner and outer shells
- Printed Reinforced Concrete: Reinforcement is embedded in-line from the nozzle of the printer
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Into the Future:
3D Printing vs Traditional Wall Costs
Conventional Wall System
ICON Wall System
Advanced materials
FormCrete is our proprietary, next-gen building material.
Mixed on site and pumped directly to the printer, FormCrete combines locally sourced ingredients to create a new category of high-performance cementitious construction.
FormCrete reduces embodied carbon both within the material itself and through locally sourced inputs that lower procurement emissions. The mix achieves a 24% carbon reduction, equivalent to 85 kgCO₂e per cubic yard, while delivering compressive strengths of
2,500–3,500 psi. By building with FormCrete, we can meaningfully lower construction-related environmental impact while delivering durable, energy-efficient structures designed for long-term sustainability.
Initial Slump
8-10 inches
Unit Weight
120-124 pcf
Freeze-Thaw
DF > 80% @ 300 cycles
compressive strength
Min 3000 psi
Drying Shrinkage
<0.055%
Regulatory
ICC-ES AC 509 ESR-4652
Per ICC-ES report ESR-4652, ICON’s 3D-printed concrete wall systems comply with the Florida Building Code, including High-Velocity Hurricane Zone requirements, for design wind loads up to 100 psf (4788 Pa), when constructed and reinforced as specified.
ASTM E119 Load Bearing Wall Fire Test
ICON Wall System passed ASTM E330, ASTM E1886, TAS 201, TAS 202, and TAS 203 testing, withstanding Level D large-missile impacts without penetration and meeting Florida Building Code requirements for Wind Zone 4 at a ±100 psf design pressure.
High Wind and Impact Report
ICON Wall System met ASTM E119-22 fire-resistance requirements, achieving a 178-minute fire-resistance rating as a load-bearing wall assembly and successfully passing the hose-stream test. The assembly maintained structural integrity under load and limited heat
transmission within the standard’s acceptance criteria throughout the duration of the test.
ASTM e331 Rain Resistance Test
Third party conducted ASTM E331 water penetration testing on ICON Wall System with clear coat, and passed water penetration test for wind driven rain.
White Paper
3.10.2024
MIT Concrete Sustainability Hub White Paper
Combined with ICON’s robotic wall system, FormCrete delivers a scalable, low-carbon alternative to stick-framed construction, validated by a 2024 MIT study showing reduced embodied and operational impacts.
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Specifications
2.13.2025
Thermal Performance Spec Sheet
ICON’s wall system combines 3D-printed concrete and spray foam insulation to create an insulated dual-bead structure that reduces thermal bridging while preserving strength and performance.
white paper
5.27.2025
Wall System General Performance Summary
ICON’s 3D-printed double-shell wall system extrudes rapidly curing CarbonX to form a monolithic, load-bearing assembly with alternating reinforced cores, a continuous insulated cavity for MEP routing, and uninterrupted load paths that eliminate traditional formwork
and jointed construction.