UK National Grid Trials Low‑Carbon 3D‑Printed Foundations for Substations

UK National Grid has launched a ground‑breaking trial of 3D‑printed concrete foundations at its Deeside Innovation Centre, in collaboration with Hyperion Robotics and the University of Sheffield. This marks the UK’s first application of additive manufacturing in utility‑scale substation construction.

Project Highlights

• Innovation partners: National Grid, Hyperion Robotics (Finland), University of Sheffield

• Technology: Additive manufacturing to produce reinforced concrete foundations using bespoke low‑carbon mixes

• Purpose: Start with non‑critical structures (such as pole bases), then expand to full substation foundations

• Testing stage: Completed in Finland and at Sheffield, with field trials at Deeside later in 2025

Sustainability and Material Savings

• 70% less concrete used compared to traditional methods

• 80% less soil displacement during installation

• 65% reduction in embodied carbon through optimised geometry and materials

• Across the UK network, this could save up to 705 tonnes of concrete and 323 tonnes of CO₂ over a decade, alongside £1.7 m in consumer savings

Strength and Efficiency Gains

• 3D‑printed foundations have shown up to four times the strength compared to standard castings

• Designs are lighter, facilitating easier transport and placement

• Construction hours are reduced by around 50%, improving safety and efficiency on site

Risk Evaluation

Technical Risks

• Moving from prototypes to load‑bearing structures requires rigorous structural validation

• Adapting additive techniques to harsh environments and varying soil conditions introduces complexity

Operational Risks

• Dependence on Finnish manufacturing and logistics must be managed to avoid project delays

• Field deployment at scale will require new processes and standards

Regulatory Risks

• The innovative nature of these foundations demands regulatory approval and updated technical standards

Impact Assessment

Environmental Impact

• Potential for major reductions in embodied carbon across the network

• Less excavation and transport means reduced disturbance and lower emissions

Economic Impact

• Consumer savings could flow through lower operational and capital costs

• Early adopters like National Grid may benefit from patentable methods and repositioning as sustainability leaders

Industry Impact

• The trial may set a benchmark for infrastructure innovation

• It opens doors for additive manufacturing in other civil engineering works

Delivery Partners and Roles

• Hyperion Robotics: Designs and prints foundations

• University of Sheffield: Handles lab testing and structural validation

• National Grid: Oversees field testing at Deeside and sponsors via Ofgem’s Innovation Allowance

• Manufacturing partner: Finnish foundry for initial production

• Logistics coordinators: Manage transport from Finland to UK sites

Looking Ahead

If the Deeside trials are successful, National Grid could scale up 3D‑printed foundations throughout its transmission and distribution network. This innovation may reshape UK substation construction, pushing the industry towards cleaner, smarter infrastructure and helping meet net-zero objectives.