Materials study to implement a 3D printer system to repair road pavement potholes

InfraRob is a research project funded by the European Commission's research programme Horizon 2020 that aims to maintain integrity, performance, and safety of the road infrastructure through autonomous robotized solutions and modularization. A specific task of the project is focused on the development of a system 3D printer able to extrude a specific mixture for filling in small cracks and potholes, to be integrated with an existing small autonomous carrier. The first step of the research deals with the definition of the optimal parameters of the system 3D printer/mixture, by studying in parallel the material design and the printer design. This paper presents the study performed on a mixture chosen among those commonly used for road potholes repair. The mixture is studied to achieve and balance the different conflicting performances: consistence, flowability homogeneity, and internal structure. In addition to the basic components, the use of special additives has also been explored to improve the plasticity and adhesivity of the mixture. The first phase of tests is conducted to define the main printing controls: i) Extrudability control: materials for 3D printing need to have an acceptable degree of extrudability, which is related to the capacity of a material to pass continuously through the printing head; ii) Flowability control, to ensure the mixture can be easy-pumpable in the delivery system and easy-usable on the crack or the pothole to be filed-in; iii) Setting time control: printing material requires a certain setting time to maintain a consistent flow rate for good extrudability, thus appropriate additives are needed to control the setting time. The second phase includes in situ tests to verify the compaction of the mixture under the traffic loads. The paper presents the results of the lab and in situ tests, and the features of the chosen mix, suitable to be managed by the 3D printer.