Marat Oshakhtiev, a resident of Almaty, Kazakhstan — a city in a high-risk seismic zone — saw the cycle of destruction and construction as unsustainable.

The constant threat of earthquakes highlighted the need for more resilient building practices. This inspired him and his team to envision a future where construction waste was repurposed, reducing landfill use. Thanks to innovative technology, this vision is now becoming a reality, helping to create new jobs and opportunities.

Kazakhstan is introducing cutting edge innovations with the support of the World Bank-financed Fostering Productive Innovation Project (FPIP). This project aims to promote R&D commercialization into productive innovation to tackle a variety of economic and societal challenges, including pollution and industrial waste management.

Through the FPIP, the World Bank funds and supports multiple innovative projects, bridging the gap between research and commercialization. The project has already helped to commercialize technologies like industrial 3D printing, biodegradable plastics, solar irrigation systems, and advanced beekeeping. 

A Construction First for Central Asia

Oshakhtiev, who is a team member at BM Logistics and Trade Services Co., has successfully led the completion of Central Asia's first 3D printed house in Almaty, adhering to strict seismic regulations.

Using extra strong concrete typically reserved for highly loaded structures like skyscrapers and bridges, and other seismic precautions, the house is made to withstand earthquakes of magnitude seven on the Richter scale. The 100 m² (1076 SF) building was constructed in less than two months, with the walls printed in just five days. To cope with the extreme temperature variations in Kazakhstan, the building also incorporates expanded polystyrene concrete for insulation.

Oshakhtiev's company is a graduate of the Productive Sector Consortia Grant Program implemented under the FPIP, supporting them to successfully utilize industrial 3D printing technologies to construct buildings and materials from concrete waste. 

“Embracing modern technologies is essential in today’s world. With the World Bank support, we are staying at the forefront of technological advancements with 3D construction printing within our country. With this project, our company has confidently stepped into the future, addressing Kazakhstan’s urgent need for earthquake-resistant, modernized, efficient, and resilient housing solutions,” said Oshakhtiev.

The Innovation: Combining 3D Printing and Concrete Recycling

This project combined two existing technologies: 3D printing and concrete recycling. The innovation lies in the integration of these technologies.

Typically, a 3D printer requires a special concrete mix supplied by the equipment producer, as regular concrete isn’t suitable. However, the project team developed a process to recycle construction waste to produce the required concrete mixture locally.

This innovative approach allows for greater design flexibility and precision, enabling the creation of complex structures with minimal waste. The method not only cuts cost and reduces material waste but also promotes recycling and enhances the efficiency of sustainable construction processes.

A mobile crushing plant and magnetic separator efficiently process and repurpose concrete waste and reinforcing metals, enhancing resource circularity. The optimized printing process minimizes idle time and emissions, promoting energy-efficient production.

3D printing is providing upskilling opportunities for construction workers. The industry is evolving to incorporate jobs related to not only the printing process but also research and optimization, creating software, and providing training and certification for specialists.

Traditional roles are evolving, enabling construction workers to transition to new positions such as design specialists, quality assurance professionals, and technology operators. This shift is enhancing the skill set of the workforce and creating new career paths, contributing to economic growth and job creation.           

The Future of Construction in Kazakhstan and Beyond

The project site is strategically located near many construction sites in Boralday in the Almaty region of Kazakhstan, making it easier to supply and transport concrete waste directly to the production facility. The project team is currently focused on expanding the production of houses and crushed stone.  They are developing special concrete mixtures adapted for 3D printing, using recycled concrete waste. The company plans to expand into the Central Asian market in the coming years.

In Kazakhstan, the construction sector has a significant carbon footprint. In 2019, it consumed 65 million tons of materials, with 30% imported. Domestic material extraction and production emit 13.9 million tons of CO2e annually, nearly 4% of the country's total annual emissions.

However, policies like the 'Nurly Zher' housing program and the 2021 Environmental Code have introduced circularity elements. These efforts led to the development of a Circular Economy Action Plan (CEAP), validated at a roundtable in January 2021 with various ministries and agencies.

The World Bank’s Summary Report Circular Economy as an Opportunity in Central Asia highlights the significant benefits of implementing the CEAP. The primary benefits come from value generated from selling secondary raw materials (US$909 million), the increased value of renovated buildings (US$354 million) and avoided costs of transportation and landfilling (US$72 million). Additionally, the country would reduce construction and demolition waste, natural resource consumption, and GHG emissions.

The construction sector has also been a significant contributor to employment growth in Kazakhstan. From 2003-2013, employment in construction accounted for 21% of the total increase in employment in the country, making it one of the top sectors for job creation.

By adopting innovative technologies, we can make construction more environmentally responsible and economically viable, paving the way for a more sustainable future while also creating valuable job opportunities.