Cut emissions with 3D-printed concrete foundations

National Grid is working to decarbonize its infrastructure while maintaining reliability and cost-efficiency. One of the key challenges is reducing emissions associated with construction materials and processes. As part of its broader decarbonization strategy, the company is exploring innovative technologies such as 3D printing to reduce embodied carbon in capital goods.

Location of the initiative: Displayed and stored at Deeside Centre for Innovation in North Wales and some further testing and installation will take place at Overton substation at Yorkshire Green scheme in the near future.

To reduce the emissions associated with traditional concrete foundations, National Grid partnered with Hyperion Robotics and the University of Sheffield to trial 3D-printedconcrete structures. These foundations were designed and manufactured in Finland, tested at full scale in Sheffield, and deployed at one of NG’s substations.

The initiative involved several key steps:

• Designing and producing 3D-printed concrete foundations tailored for substation use

• Conducting full-scale structural testing to validate performance and safety

• Deploying the foundations in a live field environment to assess operational feasibility

• Evaluating the environmental and financial impacts of the trial

Sustainability Impact

Climate

This initiative targets Scope 3 emissions, specifically Category 2: Capital Goods. By replacing traditional concrete with 3D-printed alternatives, National Grid is aiming to achieve a 65% reduction in embodied carbon. Over a 10-year period, this is expected to save approximately 323 tons of CO₂.

Nature

The use of 3D-printed foundations could result in 80% less soil displacement, thereby minimizing disruption to local ecosystems and biodiversity.

Social

The initiative is expected to reduce on-site construction hours by 50%, which will minimize disruption to local communities.

Business Impact

Benefits

The trial aims to demonstrate a 70% reduction in concrete usage, leading to significant material savings. Additionally, a streamlined production process and improved efficiencies across labour, the trial is expected to contribute to projected consumer savings of £1.7 million over 10 years.

Costs

The project was funded through Ofgem’s Network Innovation Allowance.

Impact Beyond Sustainability and Business

Co-benefits

The initiative promotes industry-wide innovation and supports the transition to more sustainable construction practices.

Typical Business Profile

This initiative is most relevant for utility companies, infrastructure developers, and energy transmission organizations. It is particularly suited to businesses with access to innovation funding and a commitment to achieving Net Zero targets.

Approach

• Establish partnerships with technology providers and academic institutions

• Design and manufacture 3D-printed components tailored to infrastructure needs

• Conduct laboratory and field testing to validate performance

• Monitor and evaluate the results to inform future deployment

Stakeholders Involved

• Project Leads: National Grid Innovation Team

• Company Functions: Engineering, Procurement, Sustainability

• Main Providers: Hyperion Robotics

• Other Stakeholders: University of Sheffield (testing partner), Murphys (Contractor)

Key Parameters to Consider

• The technology is in its early stages but shows strong potential

• Full-scale testing was conducted in 2025

• The expected lifetime of the foundations is comparable to traditional concrete

• Implementation may require regulatory approval and site-specific design adaptations

Implementation and Operations Tips

National Grid has completed the design and manufacturing of the 3D-printed concrete foundations and has tested these in laboratory and live operational environments.

Small foundations achieved an eightfold safety margin against the test criteria, while medium and large units reached around three times the expected capacity. All foundations reportedly passed the on‑site overturning tests and met or exceeded performance thresholds set by National Grid Electricity Transmission (NGET).