{"id":194356,"date":"2023-07-19T00:00:00","date_gmt":"2023-07-19T00:00:00","guid":{"rendered":"https:\/\/facfox.com\/news\/cambridge-researchers-3d-print-smart-concrete-headwall-construction-3d-printing\/"},"modified":"2023-07-19T00:00:00","modified_gmt":"2023-07-19T00:00:00","slug":"cambridge-researchers-3d-print-smart-concrete-headwall-construction-3d-printing","status":"publish","type":"post","link":"https:\/\/facfox.com\/news\/cambridge-researchers-3d-print-smart-concrete-headwall-construction-3d-printing\/","title":{"rendered":"Cambridge researchers 3D print smart concrete headwall Construction 3D Printing"},"content":{"rendered":"

Infrastructure is emerging as a key area of development for concrete 3D printing<\/a>. Cambridge researchers, working in part<\/a>nership with industry and specialist companies like Versarien, have helped develop the first 3D printed piece of concrete infrastructure to be used on a National Highways project. The 3D printed structure \u2013 a type of retaining wall known as a headwall \u2013 has been installed on the A30 in Cornwall, where it is providing real-time information thanks to Cambridge-designed sensors embedded in its structure. The sensors provide up-to-date measurements including temperature, strain and pressure. This digital twin of the wall could help spot and correct faults before they occur.<\/p>\n

Headwall structures are normally made in limited shapes from precast concrete, requiring formwork and extensive steel reinforcement. But by using 3D printing<\/a>, the team \u2013 including specialists from Costain, Jacobs and Versarien \u2013 could design and construct a curved hollow wall with no formwork and no steel reinforcement. The wall gets its strength not from steel, but from geometry instead.<\/p>\n

The wall \u2013 which took one hour to print \u2013 is roughly two meters high and three and a half meters across. It was printed in Gloucestershire at the headquart<\/a>ers of the advanced engineering company Versarien, using a robot arm-based concrete printer. Making the wall using 3D printing<\/a> significantly saves on costs, materials and carbon emissions.<\/p>\n

Over the past six years, Professor Abir Al-Tabbaa\u2019s team in the Depart<\/a>ment of Engineering has been developing new sensor technologies and exploring the effectiveness of existing commercial sensors to get better-quality information out of infrastructure. Her team has also developed various \u2018smart<\/a>\u2019 self-healing concretes. For this project, they supplied sensors to measure temperature during the printing process.<\/p>\n

Temperature variations at different layers of the 3D-printed wall were continuously monitored to detect any potential hotspots, thermal gradients, or anomalies. The temperature data will be correlated with the corresponding thermal imaging profile to understand the thermal behavior of the 3D printed wall.<\/p>\n

\u201cSince you need an extremely fast-setting cement for 3D printing<\/a>, it also generates an enormous amount of heat,\u201d said Al-Tabbaa. \u201cWe embedded our sensors in the wall to measure temperature during construction, and now we\u2019re getting data from them while the wall is on site.\u201d<\/p>\n

In addition to temperature, the sensors measure relative humidity, pressure, strain, electrical resistivity, and electrochemical potential. The measurements provide valuable insights into the reliability, robustness, accuracy, and longevity of the sensors.<\/p>\n

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The project\u2019s team at the Versarien facility <\/p>\n

A LiDAR system also was used to scan the wall as it was being printed to create a 3D point cloud and generate a digital twin of the wall.<\/p>\n

\u201cMaking the wall digital means it can speak for itself,\u201d said Al-Tabbaa. \u201cAnd we can use our sensors to understand these 3D printed structures better and accelerate their acceptance in industry.\u201d<\/p>\n

The Cambridge team developed a type of sensor, known as a PZT (Piezoceramic Lead-Zirconate-Titanate) sensor, which measures electromechanic<\/a>al impedance response and monitors changes in these measurements over time to detect any possible damage. These smart<\/a> sensors can show how 3D-printed mortar hardens over time, while simultaneously monitoring the host structure\u2019s health.<\/p>\n

Eight PZT sensors were embedded within the wall layers at different positions during the 3D printing<\/a> process to capture the presence of loading and strain, both during the construction process and service life after field installation.<\/p>\n

The team, which included experts in smart<\/a> materials, automation and robotics and data science, also developed a bespoke wireless data acquisition system. This enabled the collection of the multifrequency electromechanic<\/a>al response data of the embedded sensors remotely from Cambridge.<\/p>\n

\u201cThis project will serve as a living laboratory, generating valuable data over its lifespan,\u201d said Al-Tabbaa. \u201cThe sensor data and \u2018digital twin\u2019 will help infrastructure professionals better understand how 3D printing<\/a> can be used and tailored to print larger and more complex cement-based materials for the strategic road network.\u201d<\/p>\n

Members of the team included Dr Sripriya Rengaraju, Dr Christos Vlachakis, Dr Yen-Fang Su, Dr Damian Palin, Dr Hussam Taha, Dr Richard Anvo and Dr Lilia Potseluyko from Cambridge; as well as Costain\u2019s Head of Materials Bhavika Ramrakhyani, a part<\/a>-time PhD student in the Depart<\/a>ment of Engineering, and Ben Harries, Architectural Innovation Lead at Versarien, who is also start<\/a>ing a part<\/a>-time PhD in the Depart<\/a>ment of Engineering in October.<\/p>\n

The Cambridge team\u2019s work is part<\/a> of the Resilient Materials for Life Programme and the Digital Roads of the Future Initiative. The research is supported in part<\/a> by the Engineering and Physical Sciences Research Council (EPSRC), part<\/a> of UK Research and Innovation (UKRI), and the European Union.<\/p>\n

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You might also like:<\/h5>\n

Dubai Municipality issues first license to construct 3D printed residential villa: <\/a>\u201cThe four-meter-high structure will be printed in a single session, and the villa construction work that started recently will be part of an unprecedented global project. The villa is expected to be completed by October 2023 and will be built entirely from locally sourced concrete,\u201d the municipality reported.<\/p><\/blockquote>\n

* This article is reprinted from 3D Printing Media Network<\/a>. If you are involved in infringement, please contact us to delete it.<\/p>\n

<\/i> Author: Davide Sher<\/p>\n","protected":false},"excerpt":{"rendered":"

Infrastructure is emerging as a key area of development for concrete 3D printing. Cambridge researchers, working in partnership with industry and specialist companies like Versarien, have helped develop the first 3D printed piece of concrete infrastructure to be used on a National Highways project. The 3D printed structure \u2013 a type of retaining wall known as a headwall \u2013 has been installed on the A30 in Cornwall, where it is providing real-time information thanks to Cambridge-designed sensors embedded in its structure. The sensors provide up-to-date measurements including temperature, strain and pressure. This digital twin of the wall could help spot and correct faults before they occur.<\/p>\n","protected":false},"author":3,"featured_media":194357,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"fifu_image_url":"\/wp-content\/uploads\/2023\/07\/6635502491789037406.jpg","fifu_image_alt":"","footnotes":""},"categories":[204],"tags":[823],"class_list":["post-194356","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-architecture","tag-construction-3d-printing"],"yoast_head":"\nCambridge researchers 3D print smart concrete headwall Construction 3D Printing - FacFox News<\/title>\n<meta name=\"description\" content=\"Infrastructure is emerging as a key area of development for concrete 3D printing. 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