The construction sector is currently a major contributor to CO2 emissions, responsible for almost 40% of global energy consumption and emissions, largely due to cement production. The AM2PM project aims to revolutionise the construction industry by using 3D printing and robotics to create sustainable solutions for multistorey buildings. By focusing on advanced materials and technologies, the project seeks to reduce cement use, lower CO2 emissions, and improve the efficiency of the construction process.

The building and construction sector is at the heart of the climate crisis, accounting for approximately 37% of global CO₂ emissions and nearly 36% of final energy use -a staggering environmental footprint that demands urgent systemic transformation (Zhang, 2024). Within this, the cement industry alone contributes about 7–8% of global CO₂ emissions, primarily due to calcination and the combustion of fossil fuels during production (Chen et al. 2022; Gilfillan and Marland 2021; Sandbhor et al. 2023). Despite advances in low-carbon materials, the growing demand for infrastructure, especially in emerging economies, has nearly tripled cement-related emissions since 1990 (Chen et al. 2022).

Amidst these challenges, the EU-funded AM2PM project (Additive to Predictive Manufacturing for Multistorey Construction) introduces a visionary leap forward. This initiative leverages cutting-edge 3D concrete printing (3DCP), artificial intelligence (AI), and networked robotics to tackle carbon intensity at its core. By transitioning from additive to predictive manufacturing, AM2PM seeks to reduce material use by 50%, prevent millions of tons of CO₂ emissions, and radically cut costs, potentially saving over €11 billion annually for the European construction sector.

Cement decarbonisation through circular materials and AI integration

One of the project’s core innovations is its novel use of recycled concrete aggregates and quarry waste, addressing the double burden of resource scarcity and emissions. Traditional cement emits about 650–800 kg of CO₂ per tonne produced, but by integrating these secondary materials, AM2PM enables a 24–55% reduction in emissions, depending on the concrete mix and local supply chains (Pederneiras et al. 2022; Sandbhor et al. 2023). The advanced 3DCP mix design enhances early stiffness and buildability, eliminating the traditional compromise between printability and structural performance.

Artificial Intelligence (AI) is deployed not only for real-time quality control but also through AM2PM’s Learning-by-Printing methodology. This system performs over 1,000 automated experiments, using sensor-rich data to continuously improve geometry, strength, and curing behaviour predictions. It enables closed-loop feedback, significantly reducing error margins and material waste.

Conventional construction practices often require formworks and over-engineered components that consume excess material. In contrast, AM2PM adopts truss-like architectural geometries and mould-free fabrication, which can cut resource use by up to 50%, especially in high-load, multistorey applications. Eliminating formwork, a process that normally accounts for 30–50% of the material mass in concrete works, offers substantial ecological and economic advantages (Giergiczny et al., 2020).

The project's digital twin framework ensures not only precision but also compliance with emerging safety and regulatory standards. Cybersecurity, resilience, and interoperability with future-proof smart building technologies are embedded from the design phase.

From innovation to impact: Building the cities of the future

Though 3D printing has made headlines for small-scale homes and pavilions, AM2PM is the first major European initiative focused on scaling the technology for multistorey construction. The project sets a roadmap for broader deployment by addressing systemic hurdles: regulatory gaps, lack of material standards, and digital infrastructure integration. By engaging stakeholders across academia, industry, and policy, AM2PM lays the groundwork for a resilient, decarbonized European built environment.

As the sector prepares for the EU’s Fit for 55 and Green Deal targets, AM2PM positions Europe as a global leader in intelligent, sustainable construction - delivering buildings that are not only structurally sound but environmentally regenerative.

References

Chen, C., Xu, R., Tong, D., Qin, X., Cheng, J., Liu, J., Zheng, B., Yan, L., Zhang, Q., 2022. A striking growth of CO2 emissions from the global cement industry driven by new facilities in emerging countries. Environ. Res. Lett. 17, 044007. https://doi.org/10.1088/1748-9326/ac48b5 

Giergiczny, Z., Król, A., Tałaj, M., Wandoch, K., 2020. Performance of Concrete with Low CO2 Emission. Energies 13, 4328. https://doi.org/10.3390/en13174328 

Gilfillan, D., Marland, G., 2021. CDIAC-FF: global and national CO2 emissions from fossil fuel combustion and cement manufacture: 1751–2017. Earth System Science Data 13, 1667–1680. https://doi.org/10.5194/essd-13-1667-2021 

Maia Pederneiras, C., Brazão Farinha, C., Veiga, R., 2022. Carbonation Potential of Cementitious Structures in Service and Post-Demolition: A Review. CivilEng 3, 211–223. https://doi.org/10.3390/civileng3020013 

Sandbhor, S., Apte, S., Dabir, V., Kotecha, K., Balasubramaniyan, R., Choudhury, T., Sandbhor, S., Apte, S., Dabir, V., Kotecha, K., Balasubramaniyan, R., Choudhury, T., 2023. AI-based carbon emission forecast and mitigation framework using recycled concrete aggregates: A sustainable approach for the construction industry. AIMSES 10, 894–910. https://doi.org/10.3934/environsci.2023048 

Zhang, D., 2024. CO2 utilization for concrete production: Commercial deployment and pathways to net-zero emissions. Science of The Total Environment 931, 172753. https://doi.org/10.1016/j.scitotenv.2024.172753 

_{For media inquiries, interviews, or further information, please contact: Ivana Koláčková (FENIX TNT), ivana.kolackova@fenixtnt.cz}