A recent breakthrough in the water industry showcases the successful testing of a robotic 3D printer in challenging cold and wet conditions. United Utilities, in collaboration with ChangeMaker3D, conducted trials at the Weaverham Wastewater Treatment Works to explore innovative construction methods for essential infrastructure components like distribution chambers and manhole rings.

During the trials, the robotic printer exhibited impressive capabilities by efficiently producing manhole rings in just 45 minutes and larger distribution chambers in approximately 2.5 hours. Maintaining optimal conditions for the concrete was critical, with the team ensuring a consistent water supply temperature of 20°C despite the 6°C atmospheric temperatures, utilizing insulated Intermediate Bulk Containers (IBCs) on-site.

The partnership between United Utilities and ChangeMaker3D aims to leverage on-site 3D printing to improve efficiency, reduce costs, and lower carbon emissions in construction. Data from Jacobs suggests that employing 3D concrete printing for manholes could lead to a significant reduction in construction time by up to 70% and overall cost savings of up to 24%. This innovative process, known as “printfrastructure,” marks a transition towards integrating advanced technology with traditional construction practices, promising expedited asset production while minimizing the environmental footprint of construction activities.

United Utilities’ foray into robotic concrete printing signifies a pioneering effort within the water sector to drive infrastructure development improvements and foster skill diversification among the workforce in digital design and construction. Richard Clarke, the innovation programme manager at United Utilities, expressed satisfaction with the results of the 3D concrete printing, highlighting the potential for construction during colder temperatures, which could revolutionize winter-time construction practices across the industry.

Natalie Wadley, CEO and co-founder of ChangeMaker3D, emphasized the importance of understanding and addressing potential challenges like freeze/thaw issues and cracking, particularly in extremely cold external temperatures. However, observations from the trials at Weaverham Wastewater Treatment Works indicated no significant issues or alterations in the quality and consistency of the 3D printed layers, underscoring the viability and resilience of the technology in adverse weather conditions.

The successful testing of robotic 3D printing in cold and wet environments represents a significant milestone in advancing construction methods within the water industry. This achievement not only showcases the potential for enhanced efficiency and cost savings but also underscores the industry’s commitment to embracing cutting-edge technology to drive sustainable infrastructure development. As the sector continues to prioritize innovation, the utilization of 3D printing technologies is poised to revolutionize construction practices, setting new standards for future infrastructure projects.