# 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.

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Download PDF](https://cdn.prod.website-files.com/6981dd4dc49a03a3c838626e/6a06f3a1ca29c488dd808fe3_2%20inch%202-Bead%204%20FT%20OC%20Thermal%20Performance%20Spec%20Sheet_compressed.pdf)

### 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.

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Download PDF](https://cdn.prod.website-files.com/6981dd4dc49a03a3c838626e/6a06f33d7d13328707665c20_699c925887d677db4114db64_Wall%20System%20-%20General%20Performance_compressed.pdf)

### Basket Weave

### Chevron Pattern

### Non-Planar Surfaces