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National Grid testing low-carbon 3D-printed concrete

National Grid has launched a UK-first trial to use 3D-printed concrete foundations in electricity substations, aiming to reduce carbon emissions, waste and construction costs.

In partnership with Hyperion Robotics and the University of Sheffield, the project could signal a step change in how energy infrastructure is built.

Initial manufacturing and design is taking place in Finland, with full-scale testing at the University of Sheffield and later at National Grid’s Deeside Centre for Innovation in North Wales.

The 3D-printed foundations promise major environmental gains: 70% less concrete use, 65% lower embodied carbon – and a 50% cut in site operative hours.

If adopted across the grid, the technology could save up to 705 tonnes of concrete and 323 tonnes of CO₂ over a decade, delivering £1.7 million in consumer savings.

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