3D-printed substation bases cut concrete 56%
UK tests show 3D-printed substation foundations exceed strength targets, pass on-site trials and reduce concrete use for lower-carbon grid construction.
Image for illustrative purposes
UK: A programme of laboratory and on-site testing has confirmed that 3D-printed foundations for substations can outperform expectations, marking what is described as the first UK validation of the approach for this use.
The trials were carried out by Hyperion Robotics in collaboration with National Grid and the University of Sheffield. Laboratory testing showed particularly strong results: smaller foundations achieved an eightfold safety margin against the required criteria, while medium and large foundations reached roughly three times the anticipated capacity. All units also passed full-scale overturning tests on site and met, or exceeded, the performance thresholds set by National Grid Electricity Transmission (NGET).
The testing programme included two full-scale laboratory tests at the University of Sheffield’s Integrated Civil and Infrastructure Research Centre, covering tension and overturning moment, alongside a third full-scale overturning test at National Grid’s Yorkshire Green site. Contractor Murphy supported the on-site phase.
According to the project partners, the 3D-printed foundations used around 56 % less concrete than comparable traditional designs. As concrete accounts for a significant share of construction-related emissions, this reduction could help lower the embodied carbon of grid infrastructure.
Initial use is expected on non-critical assets such as lighting column foundations. Further trials are proposed for larger and safety-critical equipment, including post insulators and circuit breakers. Hyperion says the printed foundations are four times stronger than conventional alternatives.
The work has been supported through Ofgem’s Network Innovation Allowance, which enables energy networks to trial new technologies with potential long-term benefits. While further testing and regulatory approval are required, the partners believe 3D printing could speed up delivery of substation works while cutting material use and emissions.
Source: New Civil Engineer
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