Brief
Unveiling a leap in construction technology, National Highways implements the first-ever 3D-printed concrete headwall for its A30 upgrade project in Cornwall. This innovation paves the way for cost-effective, sustainable infrastructural development.
Insight
A breakthrough in construction technology is being trialled on the A30 Chiverton to Carland Cross upgrade in Cornwall. National Highways is testing the first-ever 3D-printed concrete headwall, replacing the traditional use of precast concrete and extensive steel reinforcement. This novel approach offers greater design flexibility, eliminating the need for steelwork and potentially reducing costs and materials.
This headwall was installed as part of a trial on one of the project’s under-road wildlife crossings. Upon completion, the scheme will feature 33 such crossings along the new 8.7-mile dual carriageway. This ambitious project is part of the Digital Roads of the Future Partnership, led by construction and engineering solutions provider, Costain, in collaboration with Versarien, the University of Cambridge, and National Highways.
The 2.3t headwall was 3D-printed using an alkali-activated cementitious material at Versarien’s operations centre in Gloucestershire. Throughout the process, researchers from Cambridge University embedded sensors into the structure to record temperature and movement data.
The decision to trial a headwall was based on its accessibility for installation and monitoring. With the headwall in place, researchers from Cambridge University will gather real-world data to expand their understanding of the technology, materials used, performance over time, and potential wider application within the construction industry.
The revolutionary design uses curves instead of straight lines, and the lack of steel reinforcement represents a significant and sustainable saving in costs and materials. This trial sets the scene for innovative, sustainable construction methods, with National Highways expressing a firm commitment to exploring such approaches in road construction and maintenance.
This project not only signifies a pivotal shift in the construction industry but also underscores the necessity for versatile solutions in combating climate change and increasing productivity in unison.
Highlight
- This project is being trialled on the A30 Chiverton to Carland Cross upgrade in Cornwall.
- National Highways is testing the first-ever 3D-printed concrete headwall, replacing the traditional use of precast concrete and extensive steel reinforcement. This novel approach offers greater design flexibility, eliminating the need for steelwork and potentially reducing costs and materials.
- Throughout the process, researchers from Cambridge University embedded sensors into the structure to record temperature and movement data.
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