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Over 1,200 prefabricated concrete facade elements for 154 apartments installed in Den Helder.
A large-scale 3D construction printing project in the Netherlands has been completed. Bruil, a Dutch construction innovator specialising in 3D printed concrete prefabrication, having installed over 1,200 prefabricated concrete elements for the renovation of 154 apartment units in Den Helder. This project has reshaped two ageing apartment buildings with 3D printed facades, an approach not previously applied at this scale in architectural renovation.
“This initiative represents an unparalleled opportunity to apply 3D concrete printing on an unprecedented scale,” said Theo Voogd, Bruil’s Market and Innovation Manager. The company’s printing apparatus is producing up to 30 facade components per week, keeping pace with the installation schedule. In addition to its design flexibility, the method is inherently sustainable, eliminating the need for disposable molds and significantly reducing concrete waste.
The Baskenweg buildings, originally constructed in the early 1970s, are undergoing a comprehensive exterior upgrade in collaboration with Kokon Architectuur & Stedenbouw and Helder Vastgoed. The renovation incorporates larger balconies and a Mediterranean-inspired aesthetic, addressing both functional and aesthetic concerns of residents. The prefabricated elements, ranging in size from 2 to 12 square metres, are replacing the buildings’ previously uniform facades, introducing texture and depth through freeform designs.
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Bruil Prefab Printing has been refining its 3D concrete printing technology for four years, culminating in the launch of a specialised production facility in Veenendaal last December. The facility’s robotic system operates on an integrated rail, fabricating facade panels, balustrades, and columns with fluid, non-traditional contours. This capability allows for rapid, customised production without the limitations of conventional formwork.
Ton op ‘t Ende, Real Estate Manager at Helder Vastgoed, highlighted the decision to renovate rather than demolish. “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 has confirmed that the 3D printed elements meet or exceed the durability of conventionally cast concrete. With the installation now complete, the project demonstrates the viability of 3D printed prefabrication in large-scale residential construction, setting a precedent for future renovations.
See: bruil
