3D concrete printer passes cold weather test

In the open air, the concrete required a consistent water supply temperature of 20 degrees, which the team achieved by using insulated IBC units (Intermediate Bulk Containers) on site.

The robotic printer was able to print the manhole rings in 45 minutes per item and 2.5 hours for a distribution chamber. 

The trial is part of United Utilities’ 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.

Statistics provided by Jacobs has shown that manhole concrete printing provides up to 70 per cent in time savings, and up 24 per cent in cost savings.

In a statement, innovation programme manager Richard Clarke said: “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."

Also called printfrastructure, this technology embeds the use of 3D printing using robotics with concrete, offering the potential to speed up the production process of new assets. In September 2022 United Utilities and ChangeMaker3D announced the successful completion of a concrete wastewater chamber using 3D printing.

ChangeMaker3D's Natalie Wadley said: "The session at Weaverham Wastewater Treatment Works 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."