Europe UK (Commonwealth Union) – In collaboration with industry partners, researchers from the University of Cambridge have achieved a groundbreaking milestone by developing the first 3D-printed concrete infrastructure for a National Highways project in England.
This innovative structure, known as a headwall, has been successfully implemented on the A30 in Cornwall. What sets this headwall apart is its incorporation of Cambridge-designed sensors embedded within its structure. These state-of-the-art sensors continuously monitor and relay real-time information, including temperature, strain, and pressure. The headwall’s “digital twin” capabilities enable the detection and rectification of faults before they escalate.
Traditionally, headwall structures were limited to specific shapes and made from precast concrete, requiring formwork and substantial steel reinforcement. However, the research team, in collaboration with experts from Costain, Jacobs, and Versarien, harnessed the power of 3D printing to design and construct a curved hollow wall, eliminating the need for formwork and steel reinforcement. Instead, the wall derives its strength from its intricate geometric design.
The 3D-printing process, performed at Versarien’s advanced engineering headquarters in Gloucestershire using a robot arm-based concrete printer, took only one hour to complete. The final headwall stands approximately two meters in height and spans three and a half meters across. By utilizing 3D printing technology, this achievement significantly reduces costs, conserves materials, and minimizes carbon emissions compared to traditional construction methods.
For the last six years, Professor Abir Al-Tabbaa and her team at the Department of Engineering have been dedicated to advancing sensor technologies and assessing the capabilities of commercial sensors to enhance the quality of information obtained from infrastructure. In addition, they have made significant strides in creating innovative “smart” self-healing concretes.
In their latest project, the team provided specialized sensors designed to measure temperature during the concrete printing process. These cutting-edge sensors play a crucial role in their pursuit of developing more efficient and resilient infrastructural solutions.
