Cambridge researchers help develop 3D printed concrete wall for National Highways project

The 3D printed headwall has a range of sensors embedded into it which provide real-time information on various aspects of its status. Credit: National Highways

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In a national first, researchers from the University of Cambridge have helped develop a 3D-printed, smart piece of concrete infrastructure for a National Highways project.

The structure, known as a headwall, was installed on the A30 in Cornwall. But the fact it was 3D printed isn’t the only innovation. The headwall also has a range of sensors – developed by a team in the university’s Department of Engineering led by Professor Abir Al-Tabbaa – embedded into it. These sensors provide real-time information, including temperature, strain and pressure.

The wall’s smart capabilities allow researchers to closely monitor several aspects, enabling them to potentially identify and fix faults before they become a problem. It is hoped that the insights provided by the sensors will enable researchers to better understand how 3D structures can be used in highway applications, potentially paving the way for them to be accepted in industry.

For the past six years, Professor Abir Al-Tabbaa’s team has been developing the sensors, as well as exploring the effectiveness of existing commercial sensors to get better-quality information out of infrastructure.

The wall took just one hour to print. It is approximately two metres high and three and a half metres across. It was printed at Versarien’s Gloucestershire headquarters using a robot arm-based concrete printer. Making the wall using 3D printing significantly saves on costs, materials and carbon emissions.

“This project will serve as a living laboratory, generating valuable data over its lifespan,” said Al-Tabbaa. “The sensor data and ‘digital twin’ will help infrastructure professionals better understand how 3D printing can be used and tailored to print larger and more complex cement-based materials for the strategic road network.”

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