National Grid trials 3D-printed concrete foundations
National Grid has partnered with Hyperion Robotics in a UK-first trial of low-carbon 3D-printed concrete foundations for substations — a move that could cut carbon, concrete use and consumer costs across the power network.
The pilot project, backed by Ofgem’s Network Innovation Allowance, will see foundations designed and manufactured by Hyperion in Finland and tested at the University of Sheffield and National Grid’s Deeside Centre for Innovation in North Wales. If successful, the approach could reduce material usage by 70%, CO₂ emissions by 65%, and save £1.7 million over 10 years.
Unlike traditional concrete foundations, the printed structures are lighter, produce less waste and require 80% less soil displacement — without compromising performance. Hyperion says the design has already proven to be four times stronger than conventional methods in earlier trials.
The trial will begin with non-critical applications, such as lighting column bases, before scaling to structural foundations for key equipment like post insulators and circuit breakers.
Fernando De los Rios, Hyperion’s CEO, described the collaboration as a “pivotal moment” in its mission to build greener and smarter. “National Grid is setting an inspiring global benchmark for innovation and sustainability in the energy sector,” he said.
Dr Muhammad Shaban, innovation engineer at National Grid, called the project a “real step forward” in low-carbon construction: “This is the first time this kind of 3D-printed alternative to concrete is being trialled for substations in the UK.”
Testing of structural performance will be led by Dr Behzad Nematollahi’s team at the University of Sheffield’s ICAIR centre.
Concrete’s decarbonisation challenge
Concrete is the second most used substance on earth after water and contributes around 8% of global CO₂ emissions. With National Grid operating over 300 substations and 7,000 kilometres of overhead lines, finding greener alternatives for foundations could have wide-reaching impact across the infrastructure sector.
Hyperion’s digitally enabled approach to design and offsite manufacture is aligned with Design for Manufacture and Assembly (DfMA) principles. The company says its methods halve on-site labour hours and offer significant lifecycle savings.
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