Automated Manhole Printing: A Smarter Way to Shape Flow Profiles

Vertico, Summum Engineering and IRS Robotics developed a way to robotically 3D print custom flow profiles inside precast manholes. The robot prints concrete directly into the base of each pit, so nobody has to climb in and shape the profile by hand.

Why custom manhole profiles are still made by hand

In the Netherlands alone, more than 50,000 manholes are produced each year. Around 10% of them need a custom flow profile.

Today those profiles are shaped manually. The work is:

• Physically demanding
• Time-consuming
• Hazardous for workers

Not surprisingly, fewer and fewer people are willing to do it.

Robotic 3D concrete printing inside the manhole

The alternative is safer and scalable: custom profiles printed by a robot inside existing precast pits. Using motion control and material logic, the robot lays down concrete layers with high precision in the base of the manhole.

This removes the need for:

• People entering tight, unsafe spaces
• Manual shaping and smoothing of complex geometry
• Time-consuming finishing work

How it works: parametric design meets in-pit printing

The system runs on a parametric digital tool that:

• Adapts in real time to different pit sizes and pipe locations
• Sends custom toolpaths to the robot
• Produces a smooth, functional flow profile every time

The operator enters the specs and prints, with no rework. The workflow runs on a complete setup, from digital input to robotic execution. See what goes into a complete 3D concrete printer setup.

The bigger picture: smarter infrastructure

The method sits between two existing options:

• Traditional precast, which is fast and cheap
• Fully printed components, which are flexible but slower

Instead of replacing the whole system, it adds automation where it matters most and keeps what already works. The goal is safer jobs, better infrastructure and more sustainable construction. Read more in our news post on automating manhole production and on our 3D concrete printing for construction page.

Credits

• Partners: Summum Engineering, IRS Robotics
• Robotic 3D concrete printing: Vertico