National Grid trials 3D-printed substation foundations
Image courtesy National Grid
National Grid is working with Hyperion Robotics and the University of Sheffield on a UK-first trial to manufacture, install and test 3D-printed substation foundations.
According to the British utility in a release, 3D printing the foundations has the potential to reduce construction-driven carbon emissions and reduce the costs to consumers of network construction.
National Grid is considering the impact of such tech across its operating substations, saying it could save up to 705 tons of concrete and 323 tons of CO2 over 10 years, and deliver £1.7 million ($2.3 million) in consumer savings versus traditional methods.
The foundations will be designed and produced in Finland by Hyperion Robotics, tested at full-scale by the University of Sheffield. Further field testing will then be carried out at National Grid’s state-of-the-art testing facility, the Deeside Centre for Innovation in North Wales, later in 2025.
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Commenting in a release was Muhammad Shaban, lead innovation engineer at National Grid Electricity Transmission:
“Our collaboration with Hyperion Robotics is a real step forward in achieving more innovative construction practices which align with our bold and ambitious commitments on sustainability.
“This trial of low-carbon 3D printed alternatives to concrete for substation foundations is the first of its kind in the UK, and has the potential to transform construction activities across the industry. The project has been funded by Ofgem’s Network Innovation Allowance, which provides an allowance to energy network licensees to fund innovation projects that have the potential to deliver longer term financial and environmental benefits for consumers.”
According to National Grid, the 3D-printed foundation design will deliver significant savings across the entire value chain, including:
- 70% reduction in concrete usage
- 80% less soil displacement
- 65% decrease in embodied carbon emissions
- 70% weight reduction compared to typical foundations
- 50% reduction in site operative hours, streamlining production
Fernando De los Rios, Hyperion’s CEO and founder, said: “Collaborating with National Grid, one of the world’s largest utility companies, marks a pivotal moment for Hyperion Robotics as we advance our mission to help the industry build smarter and greener.
“This partnership accelerates our efforts to decarbonise the construction sector through cutting-edge engineering and low carbon 3D-printed concrete structures. Through this collaboration, National Grid is setting an inspiring global benchmark for innovation and sustainability in the energy sector.”
Said Behzad Nematollahi, deputy lead of the Structural Engineering Research Group at the School of Mechanical, Aerospace and Civil Engineering at the University of Sheffield, said:
“We are delighted to be collaborating with Hyperion Robotics and National Grid on this innovative project.
“To ascertain the load-bearing capacity of the 3D-printed concrete foundations, we will conduct full-scale testing using state-of-the-art engineering testing facilities at the Intelligent Infrastructure Laboratory located at ICAIR, the Integrated Civil and Infrastructure Research Centre at the University of Sheffield.”
