A research collaboration undertaken in Brisbane is offering a fresh look at how artificial intelligence and 3D concrete printing could transform the way Australia delivers complex civil infrastructure.
By Cadell Taye, CEO, National Precast Concrete Association Australia.
With thanks to Dr. Mohammad Kangavar, Everhard Industries
The project ran from 2023 to 2025 and brought together researchers from the Queensland University of Technology (QUT) and Everhard Industries to explore how emerging digital tools can complement traditional precast manufacturing, particularly for highly customised underground structures.
Breaking convention
The work centred on developing 3D printable concrete mixes suitable for civil applications. Unlike conventional precast, where moulds add time, labour and cost, 3D printing provides a direct-to-shape method that could allow manufacturers to produce one-off components with greater speed and flexibility. This is particularly relevant for drainage, utilities and other assets that often require non-standard forms that are costly to fabricate through traditional processes.
Decarbonisation
A major focus of the project is reducing the carbon footprint of concrete. The team at QUT has been trialling mixes that incorporate supplementary materials such as sugarcane bagasse ash and fly ash, replacing part of the cement content. Early results suggest these alternative binders could support lower-carbon outcomes while still meeting the strength and durability expectations associated with civil infrastructure. With the industry facing increased regulatory and commercial pressure on emissions, this work aligns closely with broader sustainability priorities.
AI injects efficiencies
Artificial intelligence is playing an important role throughout the research, helping improve both material development and process efficiency. Rather than relying solely on physical trial-and-error, machine learning models are being used to predict mix behaviour, printability and performance before materials reach testing. This provides faster feedback loops, reduces waste and enables more targeted experimentation, which is particularly valuable when working with unconventional binders and new printing conditions.
The project also explores how AI-enabled imaging can support better quality control during printing. By automatically monitoring layer height, filament width and overall consistency, the system can detect variations much earlier in the process. For precast manufacturers, this could help improve accuracy and reliability when producing elements with complex geometries, particularly in environments where consistency is critical.
As one of the project’s lead engineers, Dr. Mohammad Kangavar, Senior Civil Engineer with Everhard Industries, notes, “AI gives us the ability to understand mix performance much earlier and with far greater accuracy. It reduces the amount of trial material needed, supports better decision making, and helps us work more confidently with new and more sustainable binders.” His comments reflect a broader shift toward integrating digital intelligence with established construction practices.
Early signs of success
The early outcomes are promising. The research team has produced printed prototypes and evaluated their structural performance, including strength development and shrinkage behaviour. These trials are helping establish an evidence base for how the technology might be adapted for real civil applications. While broad commercial use remains some distance away, the work is building a practical foundation for future adoption.
Testing continues
Further testing and clearer design frameworks will be important for industry uptake. Civil infrastructure must meet strict durability requirements, and printed elements will need to demonstrate long-term performance across varied conditions. Australia currently has no dedicated standards for 3D printed civil structures, and the project highlights the need for guidance that considers print behaviour, material characteristics and structural reliability.
Awareness increasing
Even with these challenges, the potential benefits are attracting attention. By reducing reliance on mould fabrication, accelerating prototyping and enabling cost-effective bespoke components, 3D printing could support more adaptable forms of civil construction. When paired with AI-driven optimisation and monitoring, the approach may help reduce waste, improve material efficiency and support the industry’s shift towards lower-carbon solutions.
Concrete advantages
For Australia’s construction and precast sectors, this research signals an encouraging step forward. Digital tools are moving from concept to capability, and with continued experimentation and clearer design pathways, AI-assisted 3D printed concrete may become a valuable contributor to smarter, more adaptable and more sustainable civil infrastructure.
For an industry seeking to balance sustainability, productivity and design ambition, 3D printed precast backed by AI may soon shift from research to reality.