As part of a newly launched pilot project, the British grid operator National Grid is working with Hyperion Robotics and the University of Sheffield to test the use of additively manufactured concrete foundations for substations. The aim is to reduce both CO₂ emissions and construction costs through automated production processes and resource-saving use of materials. The foundation structures used in the project are produced in Finland by Hyperion Robotics using 3D printing processes and then tested on a large scale at the University of Sheffield.
The additively manufactured foundations are made of a specialized concrete with a reduced cement content, which promises a significant reduction in grey emissions. Initial calculations assume savings of up to 323 tons of CO₂ and around 705 tons of concrete over a period of ten years if used across the board. The economic benefit is estimated at around 1.7 million pounds. The project is funded through Ofgem’s Network Innovation Allowance, which supports innovation with long-term benefits for consumers and the environment.
Dr Muhammad Shaban, Lead Innovation Engineer at National Grid Electricity Transmission, said: “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.”
In addition to environmental aspects, another focus is on increasing efficiency in the construction process. Automated production should significantly reduce the use of materials, excavation volumes and working time. The static load-bearing capacity of the structures is being investigated by the Structural Engineering Research Team at the University of Sheffield, using the testing facilities at the ICAIR center.
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.”
Dr 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.”
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