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National Grid to trial 3D-printed substation foundations in UK first
Cristina Lago Deputy Editor
(Image: National Grid)
National Grid will trial low-carbon 3D-printed concrete foundations at its testing facility in North Wales in what it says is a UK first.
The British utility company is working with Finnish startup Hyperion Robotics and the University of Sheffield to manufacture, install and test 3D-printed substation foundations.
If rolled out across all its substations, National Grid estimates the technology could save up to 705 tons of concrete and 323 tons of CO2 over a decade and deliver £1.7m in consumer savings, compared with traditional methods.
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Supply chain savings of the foundation design include a 70% reduction in concrete usage, 80% less soil displacement, 65% decrease in embodied carbon emissions, 70% weight reduction compared to typical foundations, and 50% reduction in site operative hours.
The foundations will be designed and produced in Finland by Hyperion Robotics and tested at full scale by the University of Sheffield.
Further field testing will then be carried out at National Grid’s testing facility, the Deeside Centre for Innovation in North Wales, later in 2025.
The project has been funded by Ofgem’s Network Innovation Allowance, which provides funding to energy network licensees for projects with the potential to deliver longer-term financial and environmental benefits for consumers.
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 November/December 2025 issue of Construction Management magazine is now available to read in digital format.
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