3D concrete printing beats the freeze at Weaverham Wastewater Treatment Works

United Utilities has pushed the limits of technology to print distribution chambers and manhole rings in cold, damp, and icy conditions - testing both the strength of the concrete, and its robot pourer/printer. 

The printer coped well in the open air, with the concrete requiring a consistent water supply temperature of 20 degrees, which the team managed to achieve through the use of insulated IBC units (Intermediate Bulk Containers for storing water) on site.

The robotic printer was able to print the manhole rings in 45 minutes per item, with the distribution chamber printing in 2.5 hours. 

A developing innovation partnership

The trial is part of our Engineering Innovation team collaboration with concrete printing specialists ChangeMaker3D, who are working with the water industry to test the potential of 3D concrete printing to print assets on-site safely - saving time, money, and using lower carbon materials.

Statistics provided by Jacobs has shown manhole concrete printing to provide up to 70% in time savings, and up 24% in cost savings.

Innovation Programme Manager Richard Clarke says:

“We are extremely happy with the results of our 3D concrete printing work. Being able to print at lower temperatures, in this case six degrees Celsius, really opens the door to winter time construction across our industry. Over the coming months we look forward to getting our new 3D printed distribution chamber operational."

ChangeMaker3D's Natalie Wadley said:

"The session at Weaverham WwTW enabled us to understand any adjustments that might need to be made to the printing process. We wanted to understand the potential impact of issues like freeze/thaw and cracking, with external temperatures being so cold and the material being 50 degrees upon printing.

"So far, we've observed no notable issues or changes to the quality and consistency of the 3D printed layers."

What does 3D concrete printing involve?

Also termed ‘printfrastructure,’ this innovative technology embeds the use of 3D printing using robotics with concrete, offering the potential to significantly speed up the production process of new assets, provide the potential for a reduced carbon footprint in construction, and create opportunities for the development of new skills in digital design and construction.