Performance Assessment of Topologically Optimised 3D Printable Concrete Sewer Cross-Section Using Finite Element Simulation

The rapid urbanization process has brought to the forefront the critical issue of wastewater discharge from households, which includes grey, brown, and black water. Traditional sewer systems, particularly precast concrete sewers pose various challenges, such as durability concerns, substantial transportation costs, space requirements, and limited flexibility in terms of form and geometry. In response to these challenges, this study introduces an engineered and durable cross-section for 3D concrete printed sewers, offering on-site deployment with enhanced flexibility in shape and geometry. This research is carried out through several key steps. First, sustainability is prioritized by utilizing recycled concrete aggregates in combination with ground granulated blast furnace slag (GGBFS—a byproduct of steel iron industry) based alkali activation during the printing process. Second, the sewer cross-section is topologically optimized to withstand the pure compression forces it encounters. Third, the design incorporates durability considerations to provide superior protection against sewer crown corrosion. The insights gained from this study will empower sewer designers to create robust, durable sewer systems by employing topologically optimal cross-sections and sustainable design practices. By addressing the pressing issue of wastewater discharge through innovative 3D concrete printing technology and sustainable materials, this research contributes to the development of 2.8 times structurally more efficient and resilient urban infrastructure, benefiting both urban planners and the environment.