Advanced materials engineering group Versarien plc has completed the construction phase of a civil engineering project, which leans on 3D printing technology. The project has been conducted with a subsidiary of Costain Group plc, a construction and engineering company.
Together, they have been developing designs and bringing into production a 3D printed headwall. These headwall structures are traditionally fabricated from precast concrete, with extensive steel reinforcement, and with limitations on the shape of structure that can be precast.
Versarien’s technical expertise lies in the use of an AACM – alkali-activated cementitious material – and 3D printing to create a curved form headwall that is naturally strong and therefore does not need the same reinforcement. This approach would have enabled steel to be entirely removed from the walls of the structure.
During the 3D printing process, a series of sensors have been installed in the structure. This sensor data includes temperature and movement from the point of printing all the way to the structure’s performance on site. The constructed headwall is due for delivery and installation on one of Costain’s projects for National Highways shortly.
“In utilising Versarien’s materials engineering expertise and understanding of the latest techniques, we have highlighted how new technologies can be employed to provide a solution to improve product performance, lower cost and reduce the carbon footprint. We believe this represents the first use of 3D construction on a National Highways project and we look forward to the headwall being installed, demonstrating the viability and attractiveness of using this technology and Versarien’s know-how on future projects”, Neill Ricketts, Chief Executive Officer of Versarien states.
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