National Grid is trialling the use of 3D printing to make reinforced concrete substation foundations.
It is working with Hyperion Robotics, a Finnish company whose technology uses additive manufacturing techniques for the production of precast concrete. Hyperion claims that its method uses less material and is therefore more efficient.
The collaboration aims to optimise grid development through the automated production of low-carbon foundations.
The project will first explore the feasibility of this technology for non-critical structures, such as lighting column foundations. The initiative could serve as a stepping stone for the trial of low carbon 3D printed foundations for larger assets, such as post insulators and circuit breakers, with the potential to unlock greater savings in future. Hyperion Robotics claims that, despite using fewer materials, its foundations are four times stronger than traditional methods.
The foundations will be designed and produced in Finland by Hyperion Robotics and tested by the University of Sheffield. Further field testing will then be carried out at National Grid鈥檚 own testing facility, the Deeside Centre for Innovation in North Wales, later in 2025.
It is claimed that the 3D printed foundation's design saves 70% of the material, resulting in 80% less soil displacement and reduced weight for transportation. Throughout the lifecycle from design to installation, 65% less CO2 is produced, it is also claimed.
It is suggested that were the technique to be rolled out across National Grid substations, it could save up to 705 tonnes of concrete and 323 tonnes of CO2 over a 10-year period, saving 拢1.7m.
Muhammad Shaban, lead innovation engineer at National Grid Electricity Transmission, said: 鈥淥ur 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鈥檚 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.鈥�
Hyperion chief executive Fernando De los Rios added: "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.聽 Through this collaboration, National Grid is setting an inspiring global benchmark for innovation and sustainability in the energy sector."
The project has been funded by Ofgem鈥檚 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.
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