A key milestone in commercial 3D construction for America’s largest coffee company, the innovative project was a collaboration between Starbucks, Germany-based PERI 3-D Construction and Denmark-based COBOD International, a global leader in 3D construction printing. St. Louis, MO-based NewGround was the architect on the project.

Opened on May 2 following a five-month construction schedule, the 1,400-square-foot, grab-n-go Starbucks at 2491 Boca Chica Blvd. features a drive-thru lane and walk-up window. Its 3-D printed concrete walls were built using a computer-controlled robotic arm that poured tube-like concrete layers, one on top of another, to form the building’s rectangular footprint.

Case Engineering’s structural team, led by Principal/Senior Structural Engineer Stephen Sacco, P.E., collaborated with NewGround’s architects and the 3-D concrete printing company at every step of the way from concept planning through construction to ensure the overall success of the project.

Case’s structural design for the building included perimeter concrete columns cantilevered from the foundations at regular spacings to resist high wind loads at the site, which is located near the Gulf Coast at the U.S.-Mexico border. Concrete columns were also designed to support the exterior 3-D printed concrete skin to protect it against horizontal wind loading, while wood trusses were specified for the roof.

Case Structural Engineer Nick McFarland, who helped engineer the Brownsville Starbucks, says utilizing 3-D concrete printing to build prototypical, cookie-cutter quick serve restaurants will continue to grow in popularity, with some key structural considerations.

“The main challenge to consider in terms of structural engineering when designing 3-D printed concrete structures, much like other types of buildings, is ensuring there is a concise, direct load-path for gravitational vertical and lateral forces such as wind and earthquake loading,” said McFarland. “The load path for a 3D printed concrete structure will be different from those of more conventional structures, however, so these may require more creative structural solutions to resolve.”

Case’s MEP engineers worked alongside the structural team and COBOD International to design locations for all electrical conduits and domestic water and sanitary piping within the building’s walls prior to the 3-D concrete printing process.

“Once the concrete walls are 3-D printed, you cannot to drill into them, as it would compromise the structure, so all of our MEP design work had to be finalized upfront as part of the final 3-D print program for the walls,” said Case Project Manager Devin Klein. “It was a bit of a challenge because we knew there could be no changes during the MEP installation phase. We were honored to have worked on such an innovative project.”