Method Statement: On‑Site 3D Concrete Printing of Building Walls (Robotic Extrusion) – Method Statement
AI-assisted method statement with matching ITP, PDF download, and Excel export.
More than a static template
Unlike a downloadable Word or PDF template, this method statement is an AI-assisted editable starting point connected directly to a matching Inspection and Test Plan. Every section is structured, project-adaptable, and ready to export.
- AI-assisted drafting — Customize every section with AI for your specific project scope.
- Linked ITP — A matching inspection and test plan is generated alongside the method statement.
- Multiple export formats — Download as a formatted PDF or editable Excel spreadsheet.
- Editable starting point, not a final document — Review, verify, and adjust all content against your project requirements before use.
Static template vs. Quollnet workflow
| Feature | Static template | Quollnet |
|---|---|---|
| Project-specific content | Manual fill-in required | AI-assisted customization |
| Linked ITP | Separate document, no link | Matching ITP included |
| Export formats | Usually PDF only | PDF and Excel |
| Structured sections | Free-form layout | 13 standardized sections |
| Saved to your account | Local file only | Cloud-saved, reusable |
| Content accuracy | You verify everything | AI-assisted, you still verify |
| Cost | Often free but time-intensive | Free to customize and download |
What you can customize
When you save this method statement to your account, every section becomes editable. The following 13 sections are included:
- Scope — Defines the activity and its boundaries.
- References — Standards, specifications, and drawings.
- Responsibilities — Roles and accountabilities.
- Resources — Labour, plant, and equipment summary.
- Materials — Materials and compliance requirements.
- Equipment — Tools and equipment details.
- Prerequisites — Hold points and pre-conditions.
- Method sequence — Step-by-step construction sequence.
- Safety controls — HSE risk controls and PPE.
- Environmental controls — Environmental mitigation measures.
- QA/QC — Quality inspection and test requirements.
- ITP — Inspection and Test Plan table (has its own page).
- Attachments — Referenced drawings and documentation.
Why this method statement is used
This method statement is used to define and communicate the approved procedure for carrying out method statement: on‑site 3d concrete printing of building walls (robotic extrusion) on site. It ensures the work is planned in advance, the correct resources and controls are in place, and all personnel understand responsibilities, sequence, quality requirements, and safety controls before work begins. It aligns site execution with the documented scope and acceptance expectations.
Who uses this method statement
This method statement is used by contractors, site supervisors, project engineers, QA/QC engineers, HSE officers, consultants, and client representatives. It serves as a shared reference for planning, execution, supervision, inspection, and approval of the activity on site.
When it is prepared and submitted
The method statement is prepared before the work activity starts and submitted as part of the pre-construction documentation package for review and approval.
Who reviews or approves it
The method statement is usually submitted to the client representative, consultant, resident engineer, or project management consultant for review and approval before the work commences.
Important approval note
This method statement is an AI-assisted editable starting point, not a pre-approved document. Before use on any project, all content must be reviewed and approved by the relevant parties (superintendent, principal contractor, or client representative) in accordance with your contract and project quality plan.
For example: if your specification requires a departure from a referenced standard, that departure must be documented and approved separately — this method statement will not capture that automatically. Always verify against your applicable drawings, specifications, and regulatory requirements.
Method statement content
Scope
Work Included
- On-site 3D concrete printing (3DCP) of load-bearing and non-load-bearing walls for a low-rise building using a robotic extrusion system (gantry or robotic arm on track) with cementitious printable mortar.
- Integration with conventional strip/raft/pad foundations and roof/floor elements via mechanical and bonded connections.
- Incorporation of reinforcement strategies (e.g., vertical bars/grouted ducts, printed cavities for post-grouting, discrete anchors, fiber reinforcement as per mix design) [Verify per structural design].
- Embedding MEP conduits, boxes, sleeves, and forming openings per coordinated BIM/IFC/STEP print files.
- Dimensional control, interlayer bonding management, pre-print trial, production printing, curing, inspection, testing, and defect management.
- Deliverables: As-built survey, test results, calibration and print logs, ITP records, and handover documentation.
Exclusions (unless otherwise noted)
- Structural design and ultimate limit state verification (by Designer/Engineer of Record).
- Foundation works beyond interface preparation.
- Off-site component prefabrication (unless explicitly stated).
Mandatory vs Project-Specific
- Mandatory: Compliance with ICC 1150-2026, ISO/ASTM 52939:2023, approved mix and print parameters, ITP hold points, machine safety, and curing sufficient to meet design performance.
- Project-specific [Verify per project specifications]: Dimensional tolerances, acceptance limits (strength, density, bond), layer height, print speed, reinforcement type/spacing, MEP tolerances, curing duration, environmental limits (T/RH/wind), and any AHJ-specific approvals.
Key Assumptions
- Printing height within equipment safe reach envelope, typically up to one storey per print campaign [Verify].
- Printable mortar delivered via on-site silo/continuous mixer-screw pump, constant mass flow.
- Clash-free coordinated BIM model and validated G-code/print path files.
References
| Document Type | Reference / Number | Revision | Notes |
|---|---|---|---|
| ICC 1150-2026: Standard for 3D Automated Construction Technology for 3DCP | Primary compliance framework for 3DCP projects [Mandatory]. | ||
| ISO/ASTM 52939:2023: Qualification principles for structural and infrastructure 3D printing | Quality requirements and conformity assessment [Mandatory]. | ||
| ASTM C39, C42, C109, C191/C403, C157 (strength, cores, mortar cubes, set time, shrinkage) | Testing methods applicable to printable mortar/concrete [As applicable]. | ||
| ASTM C231/C173 (air), ASTM C642 (density/absorption) | Where specified for material characterization [Verify]. | ||
| ASTM C1437 / C230 (flow table) or project-approved printability tests | Used as surrogate for extrudability/consistency where specified [Verify]. | ||
| ISO 10218-2 and ISO/TS 15066 (robotic system safety), ISO 13849 (PL) | Machine safety, safeguarding, performance level for stops/E-stops [Mandatory]. | ||
| ACI 318 or EN 1992-1-1 (Eurocode 2) | Structural design reference for connections, cover, and capacity checks [As directed by Designer]. | ||
| Project Specifications, IFC/BIM models, Issued-for-Construction drawings | Governing project-specific criteria [Mandatory]. |
Responsibilities
| Role | Responsibility | Name / Party |
|---|---|---|
| Project Manager | Overall delivery, schedule, approvals, interface with Client/Engineer. | Contractor |
| Printing Supervisor / Site Engineer | Leads site execution of 3DCP, coordinates daily works, ensures print file control and equipment calibration. | Contractor |
| QA/QC Engineer | Implements ITP, inspections, tests, NCRs, calibrations, material traceability, as-built records. | Contractor |
| HSE Manager / Officer | Risk assessments, permits, site controls, training, monitoring of exposure/noise/dust, incident management. | Contractor |
| 3D Printer Operator | Operation of printer, nozzle, pump, execution of restarts, cleaning and maintenance. | Contractor |
| Surveyor / Geomatics Engineer | Primary survey control, foundation interface checks, machine datuming, as-built scanning. | Contractor |
| Materials Engineer / Plant Technician | Material design compliance, batching control, printability verification, admixture dosing. | Contractor |
| MEP Coordinator | Coordination and inspection of embedded services, openings, sleeves, and conflicts. | Contractor |
| Structural Engineer of Record (SER) | Approves structural connection details, reinforcement strategy, and accepts key hold points. | Designer |
| Client/Engineer Representative | Reviews/approves submittals, attends hold/witness points, accepts completed works. | Employer/Engineer |
Resources
| Resource Type | Description | Quantity | Remarks |
|---|---|---|---|
| Personnel | 1 per shift | ||
| Personnel | 1–2 per shift [Verify] | ||
| Personnel | 1–2 per shift | ||
| Personnel | 1 | ||
| Personnel | 1–3 [Verify] | ||
| Personnel | 2–4 [Verify] |
Materials
| Material | Specification / Grade | Quantity | Remarks |
|---|---|---|---|
| Printable cementitious mortar/concrete | Conform to ISO/ASTM 52939 qualified mix; strength class ≥ design f'c at 28 d [Verify]; max agg size per nozzle [Verify]. | ||
| Admixtures (accelerator/retarder, rheology modifiers, superplasticizer) | Project-approved dosages; compatibility proven in trial prints [Verify]. | ||
| Reinforcement steel and anchors | Grade per structural design (e.g., ASTM A615/BS 4449) [Verify]. Cover as designed. | ||
| Non-shrink grout/micro-concrete | ASTM C1107 or EN 1504-6 compliant [Verify]. | ||
| Bonding agent/key coat | Epoxy/cementitious per design and manufacturer [Verify]. | ||
| Curing compound/membranes | ASTM C309/C1315 where applicable [Verify]. | ||
| MEP embeds and conduits | Per discipline specs and fire/smoke ratings [Verify]. |
Equipment
| Equipment | Capacity / Type | Quantity | Inspection Required |
|---|---|---|---|
| 3D printing robotic gantry or arm on track | Working envelope per layout [Verify] | Pre-shift checks; annual certs [Verify] | |
| Silo/continuous mixer and screw/piston pump | Throughput matched to print speed [Verify] | Calibration per shift [Verify] | |
| Print head/nozzle assembly | Nozzle Ø 20–40 mm [Verify] | Wear check per 10 m³ or per shift [Verify] | |
| Survey and control instruments | ±2 mm @ 30 m [Verify] | Calibration certs valid | |
| Misting/curing system, curing blankets | As needed | ||
| Telehandler/mini-crane and small tools | Per lift plan [Verify] | LOLER/third-party certs [Verify] | |
| Flow table or rheometer; penetrometer/green strength jig; thermohygrometers | Per QA plan [Verify] |
Prerequisites
- Approved method statement, ITP, risk assessment, lifting plan, and print files (frozen issue with checksum/version control).
- Foundations completed, surveyed, and within tolerance; dowels/inserts as designed; bearing surface cleaned and prepared.
- Utilities mapped; site power/water confirmed; emergency arrangements in place.
- Printer base/rails installed, leveled, and load-tested/commissioned; exclusion zones and geofencing configured.
- Mix design qualified per ISO/ASTM 52939 and ICC 1150-2026; trial prints accepted.
- Weather forecast within acceptable limits (ambient temperature, wind speed, RH) [Verify per project].
- MEP coordination drawings approved; embed kits pre-assembled and tagged.
- Calibrations in date: survey kit, load cells/flow meters, admixture pumps, nozzles height sensors.
- Personnel trained on robot safety, E-stops, emergency drills, chemical hazards of cement, and restart procedures.
- Permits: Hot works (if cutting/grinding), electrical, lifting/cranage, work around robotics [Verify per project HSE plan and local regulations].
Method Sequence
| Step | Activity | Description | Responsibility | Inspection / Hold Point |
|---|---|---|---|---|
| 1 | Site setup and control | Establish control network; install printer rails/base; level to ±2 mm over full length [Verify]. Place barriers and signage; set geofenced working zone and access routes. | Surveyor / Printing Supervisor | Pre-start inspection |
| 2 | Equipment commissioning and calibration | Power-up checks; E-stop tests; home axes; calibrate nozzle height (±0.5–1.0 mm [Verify]); verify mass flow via timed discharge; verify positional accuracy via test pattern. | Printing Supervisor / OEM Technician | Witness (W) |
| 3 | Material preparation and printability checks | Load silo; set water and admixture dosing. Run pre-shift printability tests (extrudability, buildability, open time). Adjust dosages within approved limits. | Materials Engineer / Plant Tech | Witness (W) |
| 4 | Trial print (pre-production) | Print a representative wall segment with corners/openings using production parameters. Verify layer height, bead width, overhang, and interlayer bond; trial embedding of conduits/inserts. | Printing Supervisor / QA/QC | Hold (H) |
| 5 | Foundation interface preparation | Clean and pre-wet bearing surface; apply bonding agent if specified; verify dowel/insert positions per survey; install starter key or leveling bead if in design. | Site Engineer / SER | Hold (H) |
| 6 | MEP embeds pre-positioning | Set out conduits/boxes/sleeves with temporary supports. Confirm clearance from print path and reinforcement. Tag and verify IDs against model. | MEP Coordinator | Witness (W) |
| 7 | Production printing – base layers | Prime nozzle; print first 2–3 layers at reduced speed if required [Verify]. Monitor layer height (target H with ±1–2 mm tolerance [Verify]) and bead width. Verify adhesion to foundation. | Printer Operator / QA/QC | Continuous monitoring |
| 8 | Production printing – walls and openings | Proceed per approved path. Pause/slowdown near corners and openings. Install lintel strategies as designed (printed corbel, insert plates, or post-installed lintels). | Printer Operator / Site Engineer | QA surveillance |
| 9 | Reinforcement placement/post-grouting | Insert vertical bars in designed ducts at specified lifts; secure spacers to maintain cover. Post-grout ducts when print reaches required height/strength. | Site Engineer / Rebar Crew | Witness (W) |
| 10 | Embedded services during print | Place conduits/boxes between layers or within cavities at pre-planned pauses; verify clearance; seal penetrations if required. | MEP Tech / Printer Operator | QA surveillance |
| 11 | Interruptions and restart | If pause exceeds open time window, prepare cold joint: roughen/brush, mist, apply bonding agent if specified, print restart bead with overlap length [Verify]. Recalibrate nozzle height before restart. | Printing Supervisor | Witness (W) for first restart |
| 12 | Top connections/roof interface | Install bearing plates/inserts while green; or post-install anchors after curing as designed. Print final capping layers or ring beam if specified. | Site Engineer / SER | Hold (H) |
| 13 | Curing and protection | Apply curing regime immediately after print completion for each segment: misting, membranes, or blankets as specified. Maintain protection from wind, sun, rain, vibration, and impact. | Site Engineer / HSE | Daily checks |
| 14 | Dimensional control and as-built | Laser scan/survey printed walls after initial set and at completion. Compare to BIM tolerances; identify deviations for remedial works. | Surveyor / QA/QC | Witness (W) |
| 15 | Testing and sampling | Prepare printed coupons or cores per test plan for compressive strength (various orientations), density, shrinkage, and bond if specified. | QA/QC / Lab | Witness (W) for sampling |
| 16 | Defect management and repairs | Identify voids, over/under-extrusion, delamination, or misalignment. Execute approved repair: grout injection, epoxy/cementitious patch, or localized cut-out/reprint per SER approval. | Site Engineer / SER | Hold (H) for structural repairs |
| 17 | Final acceptance and handover | Complete ITP records, test results, as-builts, O&M manuals, operator manuals, warranties. Walkdown with Engineer and close punch list. | Project Manager / QA/QC | Hold (H) |
Health, Safety, and Environment (HSE) – Safety Controls
Task-Specific Hazards and Controls
1) Hazard: Robotic/gantry movement (crush/strike)
- Likely consequence: Serious injury from entrapment/impact.
- Engineering/procedural control: Physical barriers and geofencing; interlocked access gates; ISO 10218-2 compliant safeguarding; mapped exclusion zone; spotter during teaching; validated E-stops with ISO 13849 PL rating. Pre-print dry run.
- Required PPE: Helmet, hi-vis, safety boots, eye protection, gloves.
- Collective preventive measure: Hard fencing with light curtains/laser scanners where applicable.
- Inspection/permit/supervision: Pre-shift E-stop test; robot work permit and trained operator only; supervision by Printing Supervisor. [Verify per project HSE plan and local regulations]
2) Hazard: High-pressure pump/hoses
- Likely consequence: Injection injury, hose whip.
- Engineering/procedural control: Pressure relief before disconnects; whip checks; rated hoses; guards at connections; lockout-tagout (LOTO) for maintenance.
- PPE: Gloves (cut-resistant), eye/face shield when breaking lines, long sleeves.
- Collective measure: Barriers to keep others clear during priming/cleaning.
- Inspection/permit/supervision: Hose inspection each shift; pressure gauge functional; maintenance permits.
3) Hazard: Fresh cementitious material (alkaline burns)
- Likely consequence: Skin/eye burns, dermatitis.
- Control: Avoid skin contact; wash stations; training on cement hazards; avoid kneeling in wet material.
- PPE: Alkali-resistant gloves, goggles/face shield, long sleeves, waterproof boots.
- Collective: Eyewash and safety shower accessible.
- Inspection/permit/supervision: SDS on site; HSE checks for housekeeping.
4) Hazard: Silica/cement dust during mixing/silo filling
- Likely consequence: Respiratory irritation or disease.
- Control: Enclosed transfer; dust extraction; wet methods; minimize manual tipping.
- PPE: RPE P2/P3 as required; goggles.
- Collective: Local exhaust ventilation (LEV) on silo and mixer.
- Inspection/permit/supervision: Air monitoring if required; maintenance of filters.
5) Hazard: Instability/collapse of green printed walls
- Likely consequence: Structural instability, collapse.
- Control: Respect open time and buildability limits; wind shields; temporary bracing if designed; exclusion until minimum green strength achieved [Verify].
- PPE: Standard site PPE.
- Collective: Exclusion zone with signage until release criteria met.
- Inspection/permit/supervision: Supervisor sign-off before access; record green strength checks.
6) Hazard: Electrical and control systems
- Likely consequence: Shock, arc, fire.
- Control: RCD/GFCI protection; IP-rated connectors; cable routing overhead; no wet connections; LOTO for service.
- PPE: Dielectric gloves for electricians; standard PPE for others.
- Collective: Dedicated distribution boards; tagging.
- Inspection/permit/supervision: Electrical permit; periodic PAT/inspection.
7) Hazard: Lifting of pallets, inserts, rebar
- Likely consequence: Struck-by, dropped loads.
- Control: Certified slings; planned lift; trained operator; taglines; exclusion zone.
- PPE: Helmet with chin strap, gloves, boots.
- Collective: Crane/telehandler inspection and certification.
- Inspection/permit/supervision: Lifting permit and pre-lift briefing.
8) Hazard: Noise/vibration
- Likely consequence: Hearing damage.
- Control: Select low-noise equipment; schedule noisy operations; maintain equipment.
- PPE: Hearing protection when >85 dB(A) [Verify threshold].
- Collective: Noise mapping and signage.
- Inspection/permit/supervision: HSE monitoring.
9) Hazard: Slips, trips, entanglement in hoses/cables
- Likely consequence: Sprains, falls, entanglement.
- Control: Cable trays/bridges; tidy routing; anti-slip mats; housekeeping standard.
- PPE: Safety boots with slip-resistant soles.
- Collective: Walkway demarcation.
- Inspection/permit/supervision: Supervisor inspections.
10) Hazard: Hot/cold weather
- Likely consequence: Heat stress/hypothermia; material set variability.
- Control: Environmental monitoring; work/rest cycles; tents/windbreaks; adjust admixtures within approved limits.
- PPE: Weather-appropriate PPE.
- Collective: Shade, hydration stations, heating as required.
- Inspection/permit/supervision: HSE and Materials Engineer concurrence before printing in extremes.
11) Hazard: Cutting/grinding for openings or repairs
- Likely consequence: Dust, kickback, eye injuries.
- Control: Wet cutting; guards; trained users; spark control.
- PPE: RPE, eye/face shield, gloves, hearing protection.
- Collective: Hot work/permit to cut; fire watch if required.
- Inspection/permit/supervision: PTW compliance; tool inspection.
Environmental Controls
- Cementitious waste and washout: Use lined, contained washout pits; no discharge to drainage/watercourses. Allow to harden then dispose as inert waste per regulations. [Verify per project HSE plan and local regulations]
- Dust: Enclosed silo transfers; LEV on mixer/pump; dampen site roads; RPE for operators in high-dust tasks.
- Noise: Limit operations to permitted hours; maintain equipment; acoustic screens where sensitive receptors exist.
- Water use: Metering of mixing water; avoid overspray during curing; recycle non-contact water where feasible.
- Material efficiency: Optimize print paths to reduce over-extrusion. Reuse non-structural trial prints as site blocks if allowed; otherwise process as recycled aggregate [Verify].
- Energy: Use efficient motors/inverters; shut down idle equipment; consider grid over generators where available.
- Spills: Spill kits for admixtures, oils, and fuels; bunded storage; immediate cleanup and reporting.
- Light pollution: Directional task lighting only; shielded fixtures.
- Ecology: Keep exclusion from trees and habitats; avoid nighttime disturbance where restricted.
Quality Assurance and Quality Control (QA/QC)
Documentation and Controls
- Submittals: Mix design with qualification evidence (ISO/ASTM 52939), printer commissioning records, calibration certificates, print parameter matrix (layer height, speed, nozzle size), trial print report, ITP, HSE plan, MEP coordination drawings.
- Traceability: Batch number to each print segment; link to print log (file checksum), environmental readings, operator ID, and any parameter adjustments.
- Calibration: Nozzle height sensor, flow meter, admixture pumps—verify at start of each shift and after any interruption >2 h [Verify]. Record tolerances and corrections.
- Print file control: Approved/frozen files only. Version and checksum recorded in print log. Any field change requires RFI and re-approval.
Testing Regime (typical – verify project-specific)
- Fresh/Green: Printability tests (extrudability/buildability/open time) per qualified protocol; frequency: start of shift and every material change [Verify]. Green strength spot tests if specified.
- Hardened: Printed coupon or core tests for compressive strength at 7/28 days; orientations X/Y/Z as required; acceptance: ≥ design f'c [Verify]. Density/absorption (ASTM C642) if specified. Shrinkage (ASTM C157) per mix QA. Interlayer bond (shear/bend) per project procedure aligned with ISO/ASTM 52939 [Verify criteria].
- Geometry: Layer height/width checks at defined intervals; wall plumbness, thickness, and opening dimensions per tolerance plan [Verify]. As-built laser scanning for final geometry.
Nonconformance and Corrective Action
- Trigger points: Out-of-tolerance geometry, visible delamination, parameter drift beyond allowed band, failed tests.
- Actions: Pause printing; root cause analysis (materials/equipment/path); quarantine segment; issue NCR/CAR; implement approved repair or reprint; retest if required.
Records (mandatory)
- ITP checklists; calibration/commissioning reports; print logs; batch tickets; environmental logs; inspection photos; test results; NCR/CAR; as-built survey; training/competency records; permits.
Attachments
- Approved BIM/IFC models and frozen print files (versioned, checksum).
- Mix design datasheets, SDS, and material compliance certificates.
- Equipment commissioning and calibration certificates; OEM manuals.
- Risk assessments, method-specific safety plan, permits to work (robotics, lifting, electrical, hot works as applicable).
- Trial print report with measurements and photos.
- ITP forms/checklists and field inspection templates.
- Daily print logs (parameters, timestamps, environmental data) and batch/mix tickets.
- As-built survey (point cloud) and deviation reports.
- Test plans and laboratory reports.
- NCR/CAR register and repair procedures approved by SER.
- Manufacturer technical bulletins for bonding agents, curing compounds, grout.
- Emergency response plan and contacts.
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ITP preview
The first inspection activities from the linked ITP for Method Statement: On‑Site 3D Concrete Printing of Building Walls (Robotic Extrusion):
| Activity | Inspection / Test | Acceptance Criteria | Responsibility | Record |
|---|---|---|---|---|
| Submittals and approvals | Review/approval of method, ITP, mix qualification, print files (frozen version). Hold Point (H). | All mandatory documents approved prior to site works. | Contractor QA/QC; Engineer | Approval letters; transmittals |
| Equipment setup and calibration | E-stop test; nozzle height calibration; flow check; positional accuracy test. Frequency: each mobilization and after major maintenance. | Meets OEM/project tolerances [Verify]. | Printing Supervisor; OEM Tech; Engineer (W) | Calibration forms; certificates |
| Foundation interface inspection | Survey vs BIM; cleanliness; bonding agent (if specified); dowel locations/levels. | Within specified tolerances [Verify]; surface prepared/approved. | Surveyor; Site Engineer; Engineer (H) | Interface inspection report; photos |
Showing 3 of 13 inspection activities. View full ITP →
Related Inspection and Test Plan
An Inspection and Test Plan (ITP) is available for Method Statement: On‑Site 3D Concrete Printing of Building Walls (Robotic Extrusion). The ITP defines the inspection activities, acceptance criteria, hold and witness points, responsible parties, and records required to verify the work described in this method statement.
View the Method Statement: On‑Site 3D Concrete Printing of Building Walls (Robotic Extrusion) ITP →